2007 Yamaha 115 Hp Outboard Service Repair Manual.pdf by www.heydownloads.com

115C 130C

SERVICE MANUAL *LIT186160272* LIT-18616-02-72

6E5-28197-1F-11

NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use. Because Yamaha has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual.

115C, 130C SERVICE MANUAL ÂŠ2003 by Yamaha Motor Corporation, USA 1st Edition, October 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited. Printed in USA LIT-18616-02-72

HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. For instance, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol. â&#x20AC;˘ Bearings Pitting/scratches â&#x2020;&#x2019; Replace. To assist you in finding your way through this manual, the section title and major heading is given at the top of every page.

MODEL INDICATION Multiple models are mentioned in this manual and their model indications are noted as follows. Model name

115CETO

130BETO

USA and Canada name

115TR

130TR

Indication

115CETO

130BETO

ILLUSTRATIONS The illustrations within this service manual represent all of the designated models.

CROSS REFERENCES The cross references have been kept to a minimum. Cross references will direct you to the appropriate section or chapter.

IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.

NOTE: A NOTE provides key information to make procedures easier or clearer.

SPECIFICATIONS These are given in bold type at each procedure. It is not necessary to leave the section dealing with the procedure in order to look up the specifications. It is important to note the differences in specifications of models. When a procedure relates to more than one model, the main differences in specifications will be shown in a table similar to the following. Model name

115CETO

130BETO

USA and Canada name

115TR

130TR

Specification

Oil injection

HOW TO USE THIS MANUAL 1 The main points regarding removing/installing and disassembling/assembling procedures are shown in the exploded views. 2 The numbers in the exploded views indicate the required sequence of the procedure and should be observed accordingly. 3 Symbols are used in the exploded views to indicate important aspects of the procedure. A list of meanings for these symbols is provided on the following page. 4 It is important to refer to the job instruction charts at the same time as the exploded views. These charts list the sequence that the procedures should be carried out in, as well as providing explanations on part names, quantities, dimensions and important points relating to each relevant task. Example: O-ring size

39.5 × 2.5 mm: inside diameter (D) × ring diameter (d) D

5 In addition to tightening torques, the dimensions of the bolts and screws are also mentioned. Example: Bolt and screw size

10 × 25 mm

: bolt and screw diameter (D) × length (L) D L

6 In addition to the exploded views and job instruction charts, this manual provides individual illustrations when further explanations are required to explain the relevant procedure.

E 1

SYMBOLS

GEN INFO

Symbols 1 to 9 are designed as thumbtabs to indicate the content of a chapter.

SPEC

1 2 3 4 5 6 7 8 9

INSP ADJ

FUEL

LOWR

POWR 7

General information Specifications Periodic inspections and adjustments Fuel system Power unit Lower unit Bracket unit Electrical systems Trouble analysis

BRKT

–

ELEC

Symbols 0 to E indicate specific data.

0 A B C D E

TRBL ANLS A

Special tool Specified liquid Specified engine speed Specified torque Specified measurement Specified electrical value [Resistance (Ω), Voltage (V), Electric current (A)]

Symbol F to H in an exploded diagram indicate the grade of lubricant and the location of the lubrication point.

E G

H M

L LT

271

242

N LT

572

SS LT

F Apply Yamaha 2-stroke outboard motor oil (TC-W3) G Apply water resistant grease (Yamaha grease A, Yamaha marine grease) H Apply molybdenum disulfide oil

Symbols I to N in an exploded diagram indicate the grade of the sealing or locking agent and the location of the application point. I Apply Gasket Maker® J Apply Yamabond #4 (Yamaha bond number 4) K Apply LOCTITE® No. 271 (Red LOCTITE) L Apply LOCTITE® No. 242 (Blue LOCTITE) M Apply LOCTITE® No. 572 N Apply silicon sealant

CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTIONS AND ADJUSTMENTS FUEL SYSTEM POWER UNIT LOWER UNIT BRACKET UNIT

GEN INFO

SPEC

INSP ADJ

FUEL

POWR

LOWR

BRKT â&#x20AC;&#x201C;

ELECTRICAL SYSTEMS TROUBLE ANALYSIS

ELEC

TRBL ANLS

1 2 3 4 5 6 7 8 9

GEN INFO

CHAPTER 1 GENERAL INFORMATION IDENTIFICATION ............................................................................................ 1-1 SERIAL NUMBER ..................................................................................... 1-1 STARTING SERIAL NUMBERS ............................................................... 1-1 SAFETY WHILE WORKING ............................................................................ 1-2 FIRE PREVENTION ................................................................................... 1-2 VENTILATION........................................................................................... 1-2 SELF-PROTECTION.................................................................................. 1-2 OILS, GREASES AND SEALING FLUIDS................................................ 1-2 GOOD WORKING PRACTICES ................................................................ 1-3 DISASSEMBLY AND ASSEMBLY ........................................................... 1-4 SPECIAL TOOLS ............................................................................................. 1-5 MEASURING ............................................................................................ 1-5 REMOVING AND INSTALLING ............................................................... 1-7

1 2 3 4 5 6 7 8 9

GEN INFO

IDENTIFICATION

SERIAL NUMBER The outboard motorâ&#x20AC;&#x2122;s serial number is stamped on a label which is attached to the port clamp bracket. NOTE: As an antitheft measure, a special label on which the outboard motorâ&#x20AC;&#x2122;s serial number is stamped is bonded to the port clamp bracket. The label is specially treated so that peeling it off causes cracks across the serial number.

S6E51010

1 2 3 4

Model name Approval model code Transom height Serial number

1020

STARTING SERIAL NUMBERS The starting serial number blocks are as follows:

1-1

Model name

Approval model code

115TR

6E5

130TR

6L1

Starting serial number L: 1005727 X: 1005727 L: 1001179 X: 1001179 -

GEN INFO

SAFETY WHILE WORKING SAFETY WHILE WORKING

The procedures given in this manual are those recommended by Yamaha to be followed by Yamaha dealers and their mechanics.

FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling gasoline and keep it away from heat, sparks and open flames.

1030

VENTILATION Petroleum vapor is heavier than air and is deadly if inhaled in large quantities. Engine exhaust gases are harmful to breathe. When test-running an engine indoors, maintain good ventilation.

1040

SELF-PROTECTION Protect your eyes with suitable safety glasses or safety goggles, when grinding or when doing any operation which may cause particles to fly off. Protect hands and feet by wearing safety gloves or protective shoes if appropriate to the work you are doing. 1050

OILS, GREASES AND SEALING FLUIDS Use only genuine Yamaha oils, greases and sealing fluids or those recommended by Yamaha.

1060

1-2

GEN INFO

SAFETY WHILE WORKING

Under normal conditions of use, there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all-important, and by adopting good safety practices, any risk is minimized. A summary of the most important precautions is as follows: 1. While working, maintain good standards of personal and industrial hygiene. 2. Clothing which has become contaminated with lubricants should be changed as soon as practicable, and laundered before further use. 3. Avoid skin contact with lubricants; do not, for example, place a soiled wipingrag in your pocket. 4. Hands and any other part of the body which have been in contact with lubricants or lubricant-contaminated clothing, should be thoroughly washed with hot water and soap as soon as practicable. 5. To protect the skin, the application of a suitable barrier cream to the hands before working, is recommended. 6. A supply of clean lint-free cloths should be available for wiping purposes.

GOOD WORKING PRACTICES 1. The right tools Use the recommended special tools to protect parts from damage. Use the right tool in the right manner â&#x20AC;&#x201C; do not improvise. 2. Tightening torque Follow the tightening torque instructions. When tightening bolts, nuts and screws, tighten the large sizes first, and tighten inner-positioned fixings before outer-positioned ones.

1070

1-3

GEN INFO

SAFETY WHILE WORKING

3. Non-reusable items Always use new gaskets, packings, Orings, split-pins, circlips, etc., on reassembly.

1080

DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed air when disassembling. 2. Oil the contact surfaces of moving parts before assembly.

1090

3. After assembly, check that moving parts operate normally.

1100

4. Install bearings with the manufacturerâ&#x20AC;&#x2122;s markings on the side exposed to view, and liberally oil the bearings. 5. When installing oil seals, apply a light coating of water-resistant grease to the outside diameter.

1-4

GEN INFO

SPECIAL TOOLS

Using the correct special tools recommended by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvising and using improper tools can damage the equipment.

NOTE: • For U.S.A. and Canada, use part numbers that start with “J-”, “YB-”, “YM-”, “YU-” or “YW-”. • For others countries, use part numbers that start with “90890-”.

MEASURING

1 Tachometer P/N. YU-08036-A ............................ a 90890-06760 ........................... b 2 Pressure tester P/N. YB-35956 90890-06762 3 Mity vac P/N. YB-35956 90890-06756 4 Pinion height gauge P/N. YB-34432-6, YB-34432-11, YB-34432-97 90890-06702 5 Dial gauge set P/N. YU-03097 90890-01252 6 Magnetic base P/N. YU-34481 90890-06705 7 Digital caliper P/N. 90890-06704 8 Backlash indicator P/N. YB-06265 90890-06706 9 Magnetic base attaching plate P/N. YB-07003 90890-07003 0 Hydraulic pressure gauge P/N. 90890-06776 A Up-relief valve attachment P/N. 90890-06773 Down-relief valve attachment P/N. 90890-06774

1-5

GEN INFO

SPECIAL TOOLS

E B Digital tester P/N. J-39299 90890-06752 C Peak voltage adapter P/N. YU-39991 ................................ 90890-03169 ........................... D Spark gap tester P/N. YM-34487 ............................... 90890-06754 ........................... E Shimming gauge P/N. YB-34446-1, YB-34446-3, YB-34446-5, YB-34446-7 F Shimming gauge P/N. YB-34468-2 G Shimming plate P/N. 90890-06701 H Shift rod wrench P/N. YB-06052 90890-06052 I Test harness P/N. YB-06770, YB-38831, YB-38832 90890-06770, 90890-06771

1-6

a b a b

GEN INFO

SPECIAL TOOLS

REMOVING AND INSTALLING 1

1 Flywheel magnet assembly holder P/N. YB-06139 ................................ a 90890-06522 ........................... b 2 Universal puller P/N. YB-06117 ................................ a 90890-06521 ........................... b 3 Bearing/oil seal attachment P/N. YB-06196 ................................ a 90890-06610, 90890-06637 .... b 4 Driver rod P/N. YB-06071 90890-06602, 90890-06604, 90890-06605, 90890-06606, 90890-06652 5 Bearing/oil seal attachment P/N. YB-06205 90890-06663 6 Bearing/oil seal attachment P/N. YB-06194, YB-06195, YB-06199, YB-06200, YB-06376, YB-06377, YB-06378, YB-06430 90890-06620, 90890-06622, 90890-06623, 90890-06624, 90890-06630, 90890-06656 7 Piston ring compressor P/N. YU-33294 ................................ a 90890-06530 ........................... b 8 Bearing separator P/N. YB-06219 ................................ a 90890-06534 ........................... b 9 Guide plate stand P/N. 90890-06538 0 Guide plate P/N. 90890-06501

1-7

GEN INFO

SPECIAL TOOLS

E A Bearing puller P/N. 90890-06535 B Bearing/oil seal attachment P/N. 90890-06661, 90890-06662 C Ring nut wrench P/N. YB-34447 90890-06511 D Ring nut wrench extension P/N. 90890-06513 E Propeller shaft housing puller P/N. YB-06207 ................................ YB-06502 ................................ 90890-06502 F Center bolt P/N. 90890-06504 G Slide hammer P/N. YB-06096 90890-06531 H Small universal claws P/N. 90890-06536 I Bearing/oil seal depth plate P/N. YB-06213, YB-34474 .............. 90890-06603 ........................... J Drive shaft holder P/N. YB-06201 90890-06520 K Pinion nut holder P/N. 90890-06505 L Pinion nut holder attachment P/N. 90890-06507 M Bearing/oil seal attachment P/N. 90890-06607, 90890-06608, 90890-06609, 90890-06612, 90890-06631, 90890-06633, 90890-06636, 90890-06653 N Bearing puller P/N. 90890-06523 O Large universal claws P/N. 90890-06532

1-8

a b

GEN INFO

SPECIAL TOOLS

E P Slide hammer attachment P/N. YB-06335 90890-06514 Q Bearing/oil seal attachment P/N. YB-06337 R End screw wrench P/N. YB-06548 90890-06548 S End screw wrench P/N. YB-06175-1A

1-9

SPEC

CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS.......................................................................... 2-1 MAINTENANCE SPECIFICATIONS................................................................ 2-3 POWER UNIT............................................................................................ 2-3 LOWER UNIT............................................................................................ 2-5 ELECTRICAL ............................................................................................. 2-6 DIMENSIONS ........................................................................................... 2-9 TIGHTENING TORQUES .............................................................................. 2-11 SPECIFIED TORQUES ............................................................................ 2-11 GENERAL TORQUES ............................................................................. 2-13

1 2 3 4 5 6 7 8 9

SPEC

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS Item DIMENSION Overall length Overall width Overall height (L) (X) Boat transom height (L) (X) WEIGHT (without propeller) (L) (X) PERFORMANCE Maximum output Full throttle operating range Maximum fuel consumption

POWER UNIT Type Number of cylinders Displacement Bore × stroke Compression ratio Compression pressure Spark plugs (NGK) Number of carburetors Enrichment system Intake system Induction system Exhaust system Lubrication system Cooling system Ignition system Starting system Advance type

2 Model

Unit

115TR

130TR

mm (in) mm (in)

808 (31.8) 582 (22.9)

mm (in) mm (in)

1,472 (58.0) 1,599 (63.0)

mm (in) mm (in)

508 (20.0) 635 (25.0)

kg (lb) kg (lb)

163 (359.0) 167 (368.0)

kW (hp) @ r/min r/min L (US gal, lmp gal)/hr @ r/min

cm3 (cu. in) mm (in)

kPa (kg/cm2)

2-1

84.6 (115) 5,000

95.6 (130) 5,500

4,500 - 5,500 49 (12.9, 10.8) 5,500

5,000 - 6,000 56 (14.8, 12.3) 5,800

2 stroke - V 4 1,730 (105.6) 90.0 × 68.0 (3.54 × 2.68) 6.5 6.8 (1, 2 cylinders) 6.5 (3, 4 cylinders) 941 (9.41) 1,030 (10.3) BR8HS-10 BR9HS-10 2 Choke valve Reed valve Loop charge Through propeller boss Oil injection Water CDI Electric Mechanical

SPEC

GENERAL SPECIFICATIONS Item

FUEL AND OIL Fuel type Fuel rating Engine oil type Engine oil grade Engine oil capacity (engine oil tank) (sub-oil tank) Gear oil type Gear oil total quantity BRACKET Trim angle (at 12˚ boat transom) Tilt-up angle Steering angle DRIVE UNIT Gear shift positions Gear ratio Reduction gear type Clutch type Propeller shaft type Propeller direction (rear view)

E Model

Unit

115TR

130TR

Unleaded regular gasoline 91 86 2-stroke outboard motor oil TC-W3

*RON PON

L (US qt, lmp qt) L (US qt, lmp qt)

0.9 (0.95, 0.79) 10.5 (11.1, 9.2)

cm3

(US oz, lmp oz)

Hypoid gear oil SAE 90 785 (26.5, 27.7)

Degree

–4 - 16

Degree Degree

70 35 + 35 F-N-R 2.00 (26/13) Spiral bevel gear Dog clutch Spline Clockwise

* RON: Research Octane Number PON: Pump Octane Number = (RON + Motor Octane Number)/2

2-2

SPEC

MAINTENANCE SPECIFICATIONS

POWER UNIT Item CYLINDER HEADS Warpage limit

(lines indicate straightedge position) CYLINDERS Bore size Wear limit Taper limit Out-of-round limit PISTONS Piston diameter (D) Measuring point (H) Piston-to-cylinder clearance <Limit> Oversize piston diameter 1st 2nd PISTON RINGS Type (B) (T) End gap (installed) <Limit> Side clearance CRANKSHAFT Runout limit

CONNECTING RODS Small-end axial play (F) Big-end side clearance (E)

Model

Unit

115TR

130TR

mm (in)

0.10 (0.004)

mm (in) mm (in) mm (in) mm (in)

90.00 - 90.02 (3.543 - 3.544) 90.1 (3.55) 0.08 (0.003) 0.05 (0.002)

mm (in) mm (in) mm (in) mm (in)

89.920 - 89.935 (3.5402 - 3.5407) 10 (0.4) 0.080 - 0.085 (0.0031 - 0.0033) 0.135 (0.0053)

mm (in) mm (in)

90.25 (3.553) 90.50 (3.563)

mm (in) mm (in) mm (in) mm (in) mm (in)

Keystone 1.97 - 1.99 (0.0776 - 0.0783) 2.70 - 2.90 (0.1063 - 0.1142) 0.30 - 0.40 (0.012 - 0.016) 0.60 (0.024) 0.02 - 0.06 (0.001 - 0.002)

mm (in)

0.05 (0.002)

mm (in) mm (in)

2.0 (0.08) 0.12 - 0.26 (0.005 - 0.010)

2-3

SPEC

MAINTENANCE SPECIFICATIONS Item

CARBURETORS ID mark Main jet Main air jet Main nozzle (inside diameter) Pilot jet Pilot air jet Float height

Valve seat diameter Idling speed Trolling speed OIL INJECTION PUMP ID mark Oil discharge (for 3 minutes)

Bleeding REED VALVES Reed valve stopper height a

E Model

Unit

# # mm (in) # # mm (in)

115TR

130TR

6N600 176 270

6N700 180 240 3.6 (0.14)

60 16.0 ± 0.5 (0.63 ± 0.02)

mm (in) r/min r/min

1.2 (0.05) 750 ± 50 650 ± 50

cm3

(US oz, Imp oz) @ 1,500 r/min

6N600 3.20 ± 0.70 (0.108 ± 0.024, 0.113 ± 0.025)

6N700 4.80 ± 1.10 (0.162 ± 0.037, 0.169 ± 0.039) Screw

mm (in)

6.5 ± 0.3 (0.26 ± 0.01)

Warpage limit b THERMOSTATS Opening temperature Full-open temperature

mm (in)

0.2 (0.008)

˚C (˚F) ˚C (˚F)

48 - 52 (118 - 126) 60 (140)

Valve open lower limit

mm (in)

3 (0.12)

2-4

SPEC

MAINTENANCE SPECIFICATIONS

LOWER UNIT Item GEAR BACKLASH Pinion - forward gear Pinion - reverse gear Pinion shims Forward gear shims Reverse gear shims

Model

Unit

115TR

mm (in) mm (in) mm mm mm

130TR

0.32 - 0.50 (0.013 - 0.020) 0.80 - 1.17 (0.031 - 0.046) 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50

2-5

SPEC

MAINTENANCE SPECIFICATIONS

ELECTRICAL Item IGNITION SYSTEM Ignition timing Full retard Full advance Piston position CDI unit Output peak voltage lower limit (B/W – B) @ cranking 1 @ cranking 2 @ 1,500 r/min @ 3,500 r/min Charge coil Output peak voltage lower limit (R – Br) @ cranking 1 @ cranking 2 @ 1,500 r/min @ 3,500 r/min (B/R – L) @ cranking 1 @ cranking 2 @ 1,500 r/min @ 3,500 r/min Pulser coil Output peak voltage lower limit (W/R – W/Y, W/B – W/G) @ cranking 1 @ cranking 2 @ 1,500 r/min @ 3,500 r/min

Model

Unit

115TR

Degrees Degrees mm (in)

130TR

ATDC 5 BTDC 25 3.91 (0.15)

BTDC 22 3.05 (0.12)

V V V V

— 125 140 145

V V V V

170 160 165 170

V V V V

45 45 165 170

V V V V

2.5 2.5 7.0 12

* Cranking 1: Open circuit voltage. Cranking 2: Loaded circuit voltage.

2-6

SPEC

MAINTENANCE SPECIFICATIONS Item

IGNITION CONTROL SYSTEM Thermo switch (P – B) OFF → ON ON → OFF Oil level sensor (engine oil tank) Float position a “OFF” Float position b “ON” Float position c “ON” Oil level gauge (sub-oil tank) Float position d “ON” STARTING SYSTEM Fuse 1 Fuse 2 Fuel enrichment valve Resistance (L – B) STARTER MOTOR Type Output Rating Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit CHARGING SYSTEM Lighting coil Output peak voltage lower limit (G – G) @ cranking 1 @ cranking 2 @ 1,500 r/min @ 3,500 r/min

E Model

Unit

115TR

130TR

˚C (˚F) ˚C (˚F)

84 - 90 (183 - 194) 60 - 74 (140 - 165)

mm (in)

3.3 - 6.3 (0.13 - 0.25)

mm (in)

33.3 - 36.3 (1.31 - 1.43)

mm (in)

53.3 - 56.3 (2.10 - 2.22)

mm (in)

151.5 - 154.5 (5.96 - 6.08)

V-A V-A

12-30 12-20

Ω

3.4 - 4.0

kW Second

Bendix 1.1 30

mm (in) mm (in)

17.0 (0.67) 10.0 (0.39)

mm (in) mm (in)

33.0 (1.30) 32.0 (1.26)

mm (in) mm (in)

0.8 (0.03) 0.2 (0.01)

V V V V

7.0 7.0 13 11

* Cranking 1: Open circuit voltage. Cranking 2: Loaded circuit voltage.

2-7

SPEC

MAINTENANCE SPECIFICATIONS Item

POWER TRIM AND TILT SYSTEM Trim sensor Resistance (P – B) POWER TRIM AND TILT MOTOR Fluid type Brushes Standard length Wear limit Commutator Standard diameter Wear limit Mica Standard undercut Wear limit

E Model

Unit

115TR

Ω

130TR

239 - 379

ATF Dexron II mm (in) mm (in)

9.8 (0.39) 4.8 (0.19)

mm (in) mm (in)

22.0 (0.87) 21.0 (0.83)

mm (in) mm (in)

1.35 (0.05) 0.85 (0.03)

2-8

SPEC

MAINTENANCE SPECIFICATIONS

DIMENSIONS

Symbol L1 L2 L3 L4 L5 L6 L7 H1 H2 H3 H4 H6 H7 H8 H9 W1 W5 W6

Models

Unit

(L) (X) (L) (X) (L) (X)

(L) (X) (L) (X)

115TR

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

130TR 554 (21.8) 176 (6.9) — 632 (24.9) 70 (2.8) 74 (2.9) 1,007 (39.6) 1,124 (44.3) 463 (18.2) 928 (36.5) 1,055 (41.5) 544 (21.4) 191 (7.5) 515 (20.3) 642 (25.3) 764 (30.1) 839 (33.0) 191 (7.5) 15 (0.6) 741 (29.2) 291 (11.5) 409 (16.1) —

2-9

SPEC

MAINTENANCE SPECIFICATIONS

Symbol B1 B2 B3 B4 B5 B6 B9 C3 D1 D2

Models

Unit

115TR

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

130TR 125.4 (4.9) 254 (10.0) 163.5 (6.4) 50.8 (2.0) 180 (7.1) 367 (14.4) 18.5 (0.73) 82 (3.2) 13 (0.51) 55.5 (2.2)

2-10

SPEC

TIGHTENING TORQUES

SPECIFIED TORQUES Part to be tightened

Thread size

POWER UNIT Manual injection pump cable Fuel pump Intake silencer Carburetor drain plug Pilot jet plug Oil pump Recoil starter drive plate Flywheel magnet assembly Negative battery lead Power unit mount Ignition coil Starter motor lead Relay assembly lead Starter motor Intake manifold

M5 M5 M6 — — M6 M6 M20 M8 M8 M6 M6 M6 M8 1st 2nd

Reed valve Reed valve stopper Spark plug Thermostat cover Cylinder head cover Cylinder head Cooling water pressure control valve cover Exhaust port outer cover

Crankcase

Connecting rod

M6 M5 M3 M14

1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 1st 2nd 3rd 4th 5th

M6 M6 M8 M6 M6 M8 M10

2-11

Nm 4 3 3 5 3 7 6 190 7 21 8 9 4 30 4 8 3 1 25 4 8 4 8 15 30 4 8 4 8 10 18 20 40 12 37 0 12 37

Tightening torques m•kgf ft•lb 0.4 0.3 0.3 0.5 0.3 0.7 0.6 19 0.7 2.1 0.8 0.9 0.4 3.0 0.4 0.8 0.3 0.1 2.5 0.4 0.8 0.4 0.8 1.5 3.0 0.4 0.8 0.4 0.8 1.0 1.8 2.0 4.0 1.2 3.7 0 1.2 3.7

2.9 2.2 2.2 3.6 2.2 5.1 4.3 137 5.1 15 5.8 6.5 2.9 22 2.9 5.8 2.2 0.7 18 2.9 5.8 2.9 5.8 11 22 2.9 5.8 2.9 5.8 7.2 13 14 29 8.7 27 0 8.7 27

SPEC

TIGHTENING TORQUES Part to be tightened

LOWER UNIT Propeller Trim tab Lower unit Ring nut Pinion nut Gear oil drain screw Gear oil level check screw BRACKET UNIT Steering friction rod Steering handle assembly Throttle cable Shift arm Flushing hose Shift rod detent mechanism screw Upper mount Lower mount Exhaust manifold assembly Muffler Exhaust manifold Lower exhaust manifold guide Clamp bracket Trim sensor stopper Trim stopper POWER TRIM AND TILT UNIT Power trim and tilt reservoir cap Power trim and tilt reservoir Power trim and tilt motor Manual valve Tilt ram end screw Gear pump unit Gear pump Trim ram end screw

Thread size

E Tightening torques Nm m•kgf ft•lb

M18 M10 M10 — M22 — —

55 43 40 145 95 7 7

5.5 4.3 4.0 14.5 9.5 0.7 0.7

40 31 29 105 68 5.1 5.1

— — — — M5 — M12 M14 M8 M8 M8 M8 M22 M6 —

18 38 38 36 5 24 53 73 21 18 18 18 15 2 37

1.8 3.8 3.8 3.6 0.5 2.4 5.3 7.3 2.1 1.8 1.8 1.8 1.5 0.2 3.7

13 27 27 25 3.6 17 38 53 15 13 13 13 11 1.4 27

— 1/4” 1/4” — — 5/16” — —

8 5 5 4 130 9 6 80

0.8 0.5 0.5 0.4 13 0.9 0.6 8.0

5.8 3.6 3.6 2.9 94 6.5 4.3 52

2-12

SPEC

TIGHTENING TORQUES

Nut (A)

Bolt (B)

8 mm 10 mm 12 mm 14 mm 17 mm

M5 M6 M8 M10 M12

GENERAL TORQUES

General torque specifications Nm mâ&#x20AC;˘kgf ftâ&#x20AC;˘lb 5 0.5 3.6 8 0.8 5.8 18 1.8 13 36 3.6 25 43 4.3 31

This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this manual. To avoid warpage, tighten multifastener assemblies in a crisscross fashion and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads. Components should be at room temperature.

2140

2-13

INSP ADJ

CHAPTER 3 PERIODIC INSPECTIONS AND ADJUSTMENTS MAINTENANCE INTERVAL CHART .............................................................. 3-1 TOP COWLING ............................................................................................... 3-2 INSPECTING THE LOCK RELEASE (OIL INJECTION MODELS) ........... 3-2 INSPECTING THE TOP COWLING FIT .................................................... 3-2 FUEL SYSTEM ................................................................................................ 3-3 INSPECTING THE FUEL LINE.................................................................. 3-3 INSPECTING THE FUEL FILTER .............................................................. 3-3 INSPECTING THE MANUAL INJECTION (E115AMH, E115AWH) ........ 3-4 CONTROL SYSTEM........................................................................................ 3-4 ADJUSTING THE IGNITION TIMING...................................................... 3-4 SYNCHRONIZING THE CARBURETOR................................................... 3-7 ADJUSTING THE ENGINE IDLING SPEED............................................. 3-8 ADJUSTING THE CARBURETOR PICKUP TIMING.............................. 3-10 ADJUSTING THE REMOTE CONTROL SHIFT CABLE ......................... 3-12 ADJUSTING THE REMOTE CONTROL THROTTLE CABLE................. 3-12 ADJUSTING THE START-IN-GEAR PROTECTION (E115AMH, E115AWH) ......................................................................... 3-13 COOLING SYSTEM ...................................................................................... 3-14 INSPECTING THE COOLING WATER DISCHARGE ............................. 3-14 OIL INJECTION SYSTEM ............................................................................. 3-14 SYNCHRONIZING THE OIL PUMP........................................................ 3-14 AIR BLEEDING THE OIL INJECTION SYSTEM..................................... 3-15 MEASURING THE OIL PUMP DISCHARGE.......................................... 3-16 POWER TRIM AND TILT SYSTEM .............................................................. 3-18 INSPECTING THE POWER TRIM AND TILT FLUID LEVEL .................. 3-18 LOWER UNIT ................................................................................................ 3-19 INSPECTING THE GEAR OIL LEVEL ..................................................... 3-19 CHANGING AND INSPECTING THE GEAR OIL ................................... 3-19 INSPECTING THE LOWER UNIT (FOR AIR LEAKS)............................. 3-20 GENERAL ...................................................................................................... 3-21 INSPECTING THE ANODES .................................................................. 3-21 INSPECTING THE BATTERY ................................................................. 3-21 INSPECTING THE SPARK PLUGS......................................................... 3-23 LUBRICATION POINTS.......................................................................... 3-24

1 2 3 4 5 6 7 8 9

INSP ADJ

MAINTENANCE INTERVAL CHART

Use the following chart as a guide to general maintenance intervals. Dependant on operating conditions, adjust the maintenance intervals accordingly. Initial Item

Remarks

Every

10 hours 50 hours 100 hours 200 hours (Break-in) (3 months) (6 months) (1 year)

TOP COWLING Top cowling fit Inspect FUEL SYSTEM Fuel line Inspect Fuel filter Clean/inspect Carburetor Clean Manual injection Inspect/adjust (E115AMH, E115AWH) POWER UNIT Water leakage Inspect Motor exterior Inspect Exhaust leakage Inspect Cooling water passage Clean/flush CONTROL SYSTEM Carburetor synchronization Inspect/adjust Engine idling speed Inspect/adjust Remote control shift cable Inspect/adjust Remote control throttle Inspect/adjust cable Start-in-gear protection Inspect/adjust (E115AMH, E115AWH) OIL INJECTION SYSTEM Oil tank water drain Clean Oil pump lever Inspect/adjust POWER TRIM AND TILT UNIT Power trim and tilt fluid Inspect LOWER UNIT Gear oil Change Lower unit leakage Inspect Propeller Inspect GENERAL Anodes Inspect/replace Battery Inspect/charge Spark plugs Clean/adjust/ replace Wiring and connectors Adjust/reconnect Bolts and nuts Tighten Lubrication points Grease

3-1

Refer to page

3-2 3-3 3-3 4-16 3-4

— — — — 3-7 3-8 3-12 3-12 3-13

— 3-14 3-18 3-19 3-20 6-1, 6-31

(every month)

3-21 3-21 3-23 — — 3-24

INSP ADJ

TOP COWLING

INSPECTING THE LOCK RELEASE (OIL INJECTION MODELS)

1. Inspect: • Lock release Dull release → Adjust the release wire. 3001

2. Adjust: • Release wire length Adjustment steps (1) Push each locking plate down until it locks. (2) Loosen the locknuts 1. (3) Turn the adjusting nuts 2 until the ends of both wires 3 touch the locking plates 4. (4) Secure the locknuts 1.

3002

3003

INSPECTING THE TOP COWLING FIT 3 1. Inspect: • Top cowling fitting Loose/unlatched → Adjust the top cowling hook.

3010

2. Adjust: • Top cowling hook position Adjustment steps (1) Loosen the bolts 1 approximately 1/4 of a turn. (2) Move the top cowling hook either up or down slightly. (3) Secure the bolts.

3020

3-2

INSP ADJ

TOP COWLING/FUEL SYSTEM

(4) Check the top cowling fitting and repeat the adjustment if necessary. NOTE: • Moving the latch towards the seal will loosen the top cowling. • Moving the latch away from the seal will tighten the top cowling.

FUEL SYSTEM

INSPECTING THE FUEL LINE

1. Inspect: • Plastic locking tie Loosen → Retighten or replace. 2. Inspect: • Fuel line Cracks/damage/leaks → Replace. Refer to “FUEL FILTER” on page 4-1. Refer to “FUEL PUMP” on page 4-10.

3030

INSPECTING THE FUEL FILTER

Inspect: • Fuel filter element • Fuel filter cup Clogs/cracks/leaks → Replace. Foreign matter → Clean. Refer to “FUEL FILTER” on page 4-1. Å Oil injection models ı Pre-mixed models

3040

3-3

INSP ADJ

FUEL SYSTEM/CONTROL SYSTEM INSPECTING THE MANUAL INJECTION (E115AMH, E115AWH)

1. Inspect: • Injection knob gap a Out of specification → Adjust. Injection knob gap 1 - 2 mm (0.04 - 0.08 in) 3045

2. Adjust: • Injection knob gap Adjustment steps (1) Loosen the bolt slightly. (2) Adjust the position of the cable bracket 1 up to specified gap is obtained. (3) Tighten the bolt.

CONTROL SYSTEM

ADJUSTING THE IGNITION TIMING 3 1. Inspect: • Ignition timing (full advance) Incorrect → Adjust. Inspecting steps (1) Remove the flywheel magnet assembly cover. (2) Turn the flywheel magnet assembly 1 clockwise and align the timing plate 2 with the specified mark.

3050

Flywheel magnet assembly position 100A, 130B, S130B, L130B, 140B/100TR, 130TR, S130TR, L130TR: BTDC 22˚ E115A: BTDC 23˚ 115B, 115C, S115C/ C115TR, 115TR, S115TR, B115TR: BTDC 25˚ (3) Turn the magneto control lever 3 so that it contacts the full advance adjusting screw 4. (4) Check that the mark a on the flywheel magnet assembly aligns with the mark b on the pulser coil assembly. 3051

3-4

INSP ADJ

CONTROL SYSTEM

E 2. Adjust: • Ignition timing (full advance) Adjustment steps (1) Remove all of the spark plugs. (2) Remove the intake silencer. (3) Install the dial gauge 1 into cylinder #1’s spark plug hole. (4) Slowly turn the flywheel magnet assembly clockwise and stop it when the piston is at TDC. (5) Set the dial gauge to “0”. (6) Turn the flywheel magnet assembly clockwise until the dial gauge indicates the proper specification.

3052

NOTE: Turn the flywheel magnet assembly clockwise to locate BTDC.

Piston position 100A, 130B, S130B, L130B, 140B/100TR, 130TR, S130TR, L130TR: 3.05 mm (0.12 in) E115A: 3.33 mm (0.13 in) 115B, 115C, S115C/ C115TR, 115TR, S115TR, B115TR: 3.91 mm (0.15 in)

(7) Align the timing plate 2 with the specified mark on the flywheel magnet assembly. Timing plate position 100A, 130B, S130B, L130B, 140B/100TR, 130TR, S130TR, L130TR: BTDC 22˚ E115A: BTDC 23˚ 115B, 115C, S115C/ C115TR, 115TR, S115TR, B115TR: BTDC 25˚

3053

3-5

INSP ADJ

CONTROL SYSTEM

E (8) Secure the timing plate. (9) Adjust the length a of the full advance adjusting screw 3 to specification. Full advance adjusting screw length a 100A, 130B, S130B, L130B, 140B/100TR, 130TR, S130TR, L130TR: 29.0 mm (1.14 in) E115A: 24.5 mm (0.96 in) 115B/C115TR: 22.0 mm (0.87 in) 115C, S115C/115TR, S115TR, B115TR: 26.0 mm (1.02 in) (10) Disconnect the magneto control link 4 from the pulser coil assembly 5. (11) Turn the magneto control lever 6 so that it contacts the full advance adjusting screw 3. (12) Adjust the length of the magneto control link 4 so that the mark b on the flywheel magnet assembly aligns with the mark c on the pulser coil assembly 5.

3054

3. Inspect: • Ignition timing (full retard) Out of specification → Adjust. Inspecting steps (1) Turn the flywheel magnet assembly clockwise and align the timing plate and the specified mark. Flywheel magnet assembly position ATDC 5˚ (2) Turn the magneto control lever 1 so that the full retard adjusting screw 2 contacts the crankcase 3. (3) Check that the mark a on the flywheel magnet assembly aligns with the mark b on the pulser coil assembly. 3055

3-6

INSP ADJ

CONTROL SYSTEM

E 4. Adjust: • Ignition timing (full retard) Adjustment steps (1) Turn the flywheel magnet assembly clockwise and align the timing plate and the specified mark. Flywheel magnet assembly position ATDC 5˚ (2) Turn the magneto control lever 1 to the full retard position. (3) Adjust the full retard adjusting screw 2 so that the mark a on the flywheel magnet assembly aligns with the mark b on the pulser coil assembly.

3055

SYNCHRONIZING THE CARBURETOR3 NOTE: Before synchronizing the carburetor, be sure to adjust the ignition timing. 1. Inspect: • Carburetor synchronization Incorrect → Adjust. Inspecting steps (1) Remove the intake silencer. (2) While turning the lower throttle lever, check that all throttle valves become fully closed at the same time.

3-7

INSP ADJ

CONTROL SYSTEM

E 2. Adjust: • Carburetor synchronization Adjustment steps (1) Loosen the throttle stop screw 1 until it does not touch the throttle arm stopper 2. (2) Loosen the upper carburetor’s throttle lever securing screw 3 by turning them clockwise. (3) While lightly pushing the lower carburetor’s throttle lever in the direction of the arrow (fully closed), tighten the upper carburetor’s throttle lever securing screw 3 by turning them counterclockwise. (4) Turn the lower throttle lever and make sure that all of the throttle valves are synchronized.

3060

ADJUSTING THE ENGINE IDLING SPEED

NOTE: Before adjusting the engine idling speed, be sure to synchronize the carburetor and ignition timing.

3-8

INSP ADJ

CONTROL SYSTEM

E 1. Measure: • Engine idling speed Out of specification → Adjust. Engine idling speed 750 ± 50 r/min Measuring steps (1) Start the engine and allow it to warm up for a few minutes. (2) Install the tachometer onto the spark plug lead of cylinder #1.

3070

Tachometer YU-08036-A / 90890-06760

2. Adjust: • Engine idling speed Adjustment steps (1) Loosen the throttle roller adjusting screw 1.

3072

3-9

INSP ADJ

CONTROL SYSTEM

E (2) Start the engine and allow it to warm up for a few minutes. (3) Install the tachometer onto the spark plug lead of cylinder #1. Tachometer YU-08036-A / 90890-06760 (4) Turn the magneto control lever 2 so that the full retard adjusting screw 3 contacts the crankcase 4. (5) Adjust the throttle stop screw 5 in or out until the specified engine idling speed is obtained. Turning in

Engine idling speed increases.

Turning out

Engine idling speed decreases.

Engine idling speed 750 ± 50 r/min

3073

(6) Tighten the throttle roller adjusting screw 1.

ADJUSTING THE CARBURETOR PICKUP TIMING

3074

NOTE: Before adjusting the carburetor pickup timing, be sure to adjust the ignition timing, carburetor synchronization and engine idling speed. 1. Inspect: • Pickup timing Incorrect → Adjust. 3-10

INSP ADJ

CONTROL SYSTEM

E Inspecting steps (1) Turn the magneto control lever so that the full retard adjusting screw contacts the crankcase. (2) Check that the mark a on the throttle cam aligns with the center of the throttle roller 1.

3080

2. Adjust: â&#x20AC;˘ Pickup timing Adjustment steps (1) Adjust the throttle cam control link 1 to the specified length a. Throttle cam control link length 53.0 mm (2.09 in) (2) Turn the magneto control lever 2 so that the full retard adjusting screw 3 contacts the crankcase 4.

3081

(3) Loosen the throttle roller adjusting screw 5. (4) Align the mark a on the throttle cam 6 with the center of the throttle roller 7. (5) Tighten the throttle roller adjusting screw 5. 3082

3-11

INSP ADJ

CONTROL SYSTEM

ADJUSTING THE REMOTE CONTROL SHIFT CABLE 3 1. Inspect: • Shift operation Incorrect → Adjust. 2. Adjust: • Remote control shift cable length Adjustment steps (1) Loosen the locknut 1. (2) Remove the clip 2. (3) Disconnect the shift cable joint 3. (4) Set the remote control lever to the neutral position. (5) Align the center of the set pin a with the mark b on the bottom cowling. (6) Adjust the position of the shift cable joint until its hole aligns with the set pin c. (7) Install the clip and tighten the locknut.

3120

CAUTION: The remote control cable joint must be screwed in more than 8 mm (0.31 in).

3110

ADJUSTING THE REMOTE CONTROL THROTTLE CABLE 3 NOTE: Before adjusting the remote control throttle cable, be sure to adjust the ignition timing and carburetor synchronization. 1. Inspect: • Throttle operation Incorrect → Adjust. Inspecting steps (1) Turn the throttle lever fully. (2) Check the magneto control lever 1 so that it contacts the full advance adjusting screw 2. 3121

3-12

INSP ADJ

CONTROL SYSTEM

E 2. Adjust: • Remote control throttle cable length Adjustment steps (1) Loosen the locknut 1. (2) Remove the clip 2. (3) Disconnect the cable joint at the magneto control lever 3. (4) Close the throttle grip fully. (5) Turn the magneto control lever so that the full retard adjusting screw 4 contacts the crankcase. (6) Adjust the position of the throttle cable joint until its hole aligns with the set pin. (7) Install the clip and tighten the locknut.

CAUTION: The remote control cable joint must be screwed in more than 8 mm (0.31 in).

3122

ADJUSTING THE START-IN-GEAR PROTECTION (E115AMH, E115AWH) 3

1. Inspect: • Start-in-gear protection operation Incorrect → Adjust. 2. Adjust: • Start-in-gear protection wire adjuster position

3126

Adjustment steps (1) Set the shift lever in the neutral position. (2) Loosen the bolt 1. (3) Adjust the start-in-gear protection wire adjuster 2 so that the point a on the wire connector aligns with the mark b on the flywheel cover. (4) Tighten the bolt. 3127

3-13

INSP ADJ

COOLING SYSTEM/OIL INJECTION SYSTEM COOLING SYSTEM

INSPECTING THE COOLING WATER DISCHARGE 3 Inspect: • Cooling water discharge No discharge → Clean and inspect the cooling water passage. 3140

Inspecting steps (1) Place the lower unit in water. (2) Start the engine. (3) Check that water flows from the cooling water outlet.

OIL INJECTION SYSTEM

SYNCHRONIZING THE OIL PUMP

1. Inspect: • Oil pump lever position Incorrect → Adjust.

NOTE: Make sure the oil pump lever 1 touches the stopper a (fully closed position) when the throttle valves are closed.

a 3150

2. Adjust: • Oil pump lever position Adjustment steps (1) Loosen the locknut 2. (2) Disconnect the oil pump link rod joint 3. (3) Fully close the throttle valves. (4) Turn the oil pump lever 1 so it contacts the stopper a (fully closed position). (5) Adjust the position of the oil pump link rod joint until its hole aligns with the set pin on the oil pump lever 1. (6) Tighten the locknut. (7) Install the washer and clip.

CAUTION: After adjustment, make sure the oil pump lever operates properly. 3160

3-14

INSP ADJ

OIL INJECTION SYSTEM

AIR BLEEDING THE OIL INJECTION SYSTEM 3 Bleed: â&#x20AC;¢ Air bubbles (from the oil injection system) Bleeding steps (1) Fill the fuel tank with the fuel/oil mixture (50:1). Recommended fuel Fuel type Unleaded regular gasoline Fuel rating PON: 86 RON: 91 Recommended engine oil Engine oil type 2-stroke outboard motor oil Engine oil grade TC-W3

CAUTION: Only use the fuel/oil mixture (50:1) or engine malfunctions or seizure may result. (2) Disconnect the oil pump link rod joint from the oil pump lever. (3) Start the engine. (4) Turn the oil pump lever 1 and keep it in the fully-opened position until the fuel/ oil mixture flows out of the oil pump feed hoses.

3180

3-15

INSP ADJ

OIL INJECTION SYSTEM

MEASURING THE OIL PUMP DISCHARGE

Measure: • Oil pump discharge Out of specification → Check all of the oil pump components and replace any defective parts. Engine oil discharge (3 minutes/1 cylinder) 100hp, 115hp: 3.20 ± 0.70 cm3 (0.108 ± 0.024 US oz, 0.113 ± 0.025 Imp oz) 130hp: 4.80 ± 1.10 cm3 (0.162 ± 0.037 US oz, 0.169 ± 0.039 Imp oz) NOTE: When measuring the oil pump discharge, observe the following. • The engine oil temperature should be 10 30 ˚C (50 - 86 ˚F). • Before measuring the oil pump discharge, completely bleed any air from the oil injection system and make sure that no air bubbles are present in the engine oil which is flowing out of the oil feed hose. • When using the graduated cylinder, make sure no engine oil clings to its walls; otherwise, the measurement will be incorrect. • Use only the specified engine oil of the proper viscosity. If the viscosity is too high or too low, the discharge measurement will be incorrect. • Calculate the rate of discharge per minute. The longer the measurement time, the higher the accuracy of the measurement.

3190

3-16

INSP ADJ

OIL INJECTION SYSTEM

Measuring steps (1) Fill the fuel tank with the fuel/oil mixture (50:1) and fill the oil tank with engine oil. Recommended fuel Fuel type Unleaded regular gasoline Fuel rating PON: 86 RON: 91 Recommended engine oil Engine oil type 2-stroke outboard motor oil Engine oil grade TC-W3

CAUTION: Only use the fuel/oil mixture (50:1) or engine malfunctions or seizure may result. (2) Disconnect the oil pump link rod joint from the oil pump lever. (3) Move the oil pump lever 1 to the fullyopened position.

3180

(4) Remove the oil inlet hose 2 from the intake manifold. (5) Install the oil inlet hose onto the graduated cylinder. NOTE: The measuring range on the graduated cylinder should be divided into 0.1-cc increments. (6) Start the engine. (7) Set the engine idling speed at 1,500 r/min. Refer to â&#x20AC;&#x153;ADJUSTING THE ENGINE IDLING SPEEDâ&#x20AC;? on page 3-8. (8) Measure the engine oil discharge for 3 minutes.

3185

3-17

INSP ADJ

POWER TRIM AND TILT SYSTEM

POWER TRIM AND TILT SYSTEM3 INSPECTING THE POWER TRIM AND TILT FLUID LEVEL 3 Inspect: • Power trim and tilt fluid level Level is low → Add power trim and tilt fluid to the proper level. Recommended power trim and tilt fluid ATF Dexron II

WARNING When removing the power trim and tilt reservoir cap, the power trim and tilt fluid may spurt out due to internal pressure. Therefore, fully tilt up the outboard (the tilt ram assembly fully extended) and then slowly remove the power trim and tilt reservoir cap.

3195

Inspecting steps (1) Tilt the outboard all the way up and lock it with the tilt stop levers 1.

WARNING After tilting up the outboard, be sure to support it with the tilt stop levers. Otherwise, the outboard could suddenly lower if the power trim and tilt unit should lose fluid pressure. (2) Remove the reservoir cap 2 and inspect the fluid level.

3196

NOTE: The fluid level should be directly below the check hole as shown. (3) Add power trim and tilt fluid if needed, and then install the reservoir cap.

3210

3-18

Reservoir cap 8 Nm (0.8 m • kgf, 5.8 ft • lb)

INSP ADJ

LOWER UNIT

INSPECTING THE GEAR OIL LEVEL

Inspect: • Gear oil level Level is low → Add gear oil to the proper level.

CHANGING AND INSPECTING THE GEAR OIL

1. Inspect: • Gear oil Milky oil → Replace the oil seal. Slag oil → Check the gears, bearings, and clutch dog. Inspecting steps (1) Tilt up the outboard slightly. (2) Place a container under the gear oil drain screw 1. (3) Remove the gear oil drain screw and gear oil level check screw 2. 2. Fill: • Gear oil (with the specified amount of the recommend gear oil) Recommended gear oil GEAR CASE LUBE (USA) or Hypoid gear oil, SAE 90 Total amount Regular rotation models 785 cm3 (26.5 US oz, 27.7 Imp oz) Counter rotation models 715 cm3 (24.2 US oz, 25.2 Imp oz) 3220

3-19

INSP ADJ

LOWER UNIT

E Filling steps (1) Place the outboard in an upright position. (2) Insert the gear oil tube into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible. (3) Install the gear oil level check screw and then quickly install the gear oil drain screw.

3230

Gear oil level check screw 7 Nm (0.7 m • kgf, 5.1 ft • lb) Gear oil drain screw 7 Nm (0.7 m • kgf, 5.1 ft • lb)

INSPECTING THE LOWER UNIT (FOR AIR LEAKS)

Inspect: • Lower unit holding pressure Pressure drops → Inspect the seals and components. Lower unit holding pressure 70 kPa (0.7 kg/cm2, 10.2 psi) Inspecting steps

CAUTION: Do not overpressurize the lower unit. Excessive pressure may damage the oil seals. (1) Remove the gear oil level check screw. (2) Install the pressure tester into the check hole.

3240

Pressure tester YB-35956 / 90890-06762 (3) Apply the specified pressure. NOTE: The lower unit should hold the specified pressure for 10 seconds.

3-20

INSP ADJ

GENERAL

INSPECTING THE ANODES

Inspect: • Anodes 1 • Trim tab 2 (except for B115) Scales → Clean. Grease/oil → Clean. Excessive wear → Replace.

CAUTION: Do not oil, grease or paint the anode, or it will not operate properly.

3250

INSPECTING THE BATTERY

WARNING Battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive measures: • Avoid bodily contact with electrolytic fluid as it can cause severe burns or permanent eye injury. • Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): • SKIN - Flush with water. • EYES - Flush with water for 15 minutes and get immediate medical attention. Antidote (INTERNAL): • Drink large quantities of water or milk followed by milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention.

3-21

INSP ADJ

GENERAL

E Batteries also generate explosive hydrogen gas; therefore, you should always follow these preventive measures: • Charge batteries in a well-ventilated area. • Keep batteries away from fire, sparks, or open flames (e.g., welding equipment, lighted cigarettes, etc.). • DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTIC FLUID OUT OF REACH OF CHILDREN.

NOTE: • Batteries vary among manufacturers. Therefore, the following procedures may not always apply. Consult your battery manufacturer’s instructions. • First, disconnect the negative lead, then the positive lead. Inspect: • Electrolyte level Below the minimum level mark → Add distilled water to the proper level. • Electrolyte specific gravity Less than specification → Recharge the battery. Electrolyte specific gravity 1.280 at 20˚C (68˚F)

3-22

INSP ADJ

GENERAL

INSPECTING THE SPARK PLUGS

1. Inspect: • Electrodes 1 Cracks/excessive wear → Replace. • Insulator color 2 Distinctly different color → Check the engine condition. Color guide Medium to light tan color Normal Whitish color • Lean fuel mixture • Plugged jet(-s) • Air leak • Wrong setting Blackish color • Rich mixture • Excessive oil usage • Defective ignition system • Defective spark plug

3260

2. Clean: • Spark plug (with a spark plug cleaner or wire brush.)

3. Measure: • Spark plug gap a Out of specification → Regap. Spark plug gap 0.9 - 1.0 mm (0.035 - 0.039 in)

3270

3-23

INSP ADJ

GENERAL

E 4. Tighten: • Spark plug

Spark plug 25 Nm (2.5 m • kgf, 18 ft • lb)

NOTE: • Before installing the spark plug, clean the gasket surface and spark plug surface. Also, it is suggested to apply a thin film of anti-seize compound to the spark plug threads to prevent thread seizure. • If a torque wrench is not available, a good estimate of the correct tightening torque is to finger tighten a the spark plug and then tighten it another 1/4 to 1/2 of a turn b.

3280

LUBRICATION POINTS Apply: • Water resistant grease

3290

3300

3310

3-24

INSP ADJ

GENERAL

3320

3330

3340

3-25

FUEL

CHAPTER 4 FUEL SYSTEM FUEL FILTER ................................................................................................... 4-1 REMOVING/INSTALLING THE FUEL FILTER (OIL INJECTION MODELS)..................................................................... 4-1 REMOVING/INSTALLING THE FUEL FILTER (PRE-MIXED MODELS) ........................................................................... 4-3 INSPECTING THE FUEL JOINT (PRE-MIXED MODELS) ....................... 4-5 MANUAL INJECTION PUMP (E115AMH, E115AWH).................................. 4-6 REMOVING/INSTALLING THE MANUAL INJECTION PUMP ............... 4-6 INSPECTING THE BYPASS VALVE......................................................... 4-8 INSPECTING THE MANUAL INJECTION PUMP.................................... 4-8 FUEL PUMP .................................................................................................. 4-10 REMOVING/INSTALLING THE FUEL PUMP......................................... 4-10 DISASSEMBLING/ASSEMBLING THE FUEL PUMP ............................ 4-11 INSPECTING THE FUEL PUMP ............................................................. 4-13 OIL TANK ...................................................................................................... 4-14 REMOVING/INSTALLING THE OIL TANK ............................................ 4-14 CARBURETOR .............................................................................................. 4-16 REMOVING/INSTALLING THE CARBURETOR (OIL INJECTION MODELS)................................................................... 4-16 REMOVING/INSTALLING THE CARBURETOR (PRE-MIXED MODELS) ......................................................................... 4-18 DISASSEMBLING/ASSEMBLING THE CARBURETOR ........................ 4-20 DISASSEMBLING THE CARBURETOR ................................................. 4-23 INSPECTING THE CARBURETOR ......................................................... 4-23 ASSEMBLING THE CARBURETOR ....................................................... 4-24 OIL PUMP...................................................................................................... 4-25 REMOVING/INSTALLING THE OIL PUMP............................................ 4-25 INSPECTING THE CHECK VALVE ......................................................... 4-27

1 2 3 4 5 6 7 8 9

FUEL

FUEL FILTER

REMOVING/INSTALLING THE FUEL FILTER (OIL INJECTION MODELS)

4020

Order 1 2 3 4 5 6 7

Job/Part Plastic locking tie Fuel hose Fuel hose joint Fuel hose Nut Fuel filter Bolt

Qâ&#x20AC;&#x2122;ty 4 1 1 1 1 1 1

Remarks Not reusable (fuel joint-to-fuel filter) (fuel filter-to-fuel pump)

Continued on next page.

4-1

FUEL

FUEL FILTER

E 4

4020

Order 8 9 10 11 12

Job/Part Fuel filter bracket Fuel filter cap Fuel filter element O-ring Fuel filter cup

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1

Remarks

For installation, reverse the removal procedure.

4-2

FUEL

FUEL FILTER

E 4

REMOVING/INSTALLING THE FUEL FILTER (PRE-MIXED MODELS)

4010

Order 1 2 3 4 5 6 7 8 9

Job/Part Clip Fuel hose Bolt Cable guide Fuel joint Plastic locking tie Fuel hose Bolt Fuel filter

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 3 1 2 1

Remarks (fuel joint-to-fuel filter)

Not reusable (fuel filter-to-fuel pump)

Continued on next page.

4-3

FUEL

FUEL FILTER

E 4

4010

Order 10 11 12 13 14 15 16 17 18

Job/Part Bolt Fuel filter bracket Fuel filter nut Fuel filter cap Fuel filter element Spring Float O-ring Fuel filter cup

Qâ&#x20AC;&#x2122;ty 2 1 1 1 1 1 1 1 1

Remarks

For installation, reverse the removal procedure.

4-4

FUEL

FUEL FILTER

INSPECTING THE FUEL JOINT (PRE-MIXED MODELS) 1. Inspect: • Fuel joint Cracks/damage/leaks → Replace. 2. Inspect: • Fuel joint operation Pressure cannot be maintained for 10 seconds → Replace. Inspecting steps NOTE: Do not overpressurize the fuel joint. Excessive pressure may cause air to leak out. (1) Install the Mity vac onto the fuel joint as shown. 4030

Mity vac YB-35956 / 90890-06756 (2) Apply the specified pressure with the Mity vac. Fuel joint pressure 50 kPa (0.5 kg/cm2, 7.1 psi)

4-5

FUEL

MANUAL INJECTION PUMP (E115AMH, E115AWH)

REMOVING/INSTALLING THE MANUAL INJECTION PUMP

4020

Order 1 2 3 4 5 6 7 8

Job/Part Nut Knob Bolt Washer Spring Bushing Bolt Manual injection pump cable

Qâ&#x20AC;&#x2122;ty 1 1 2 1 1 2 1 1

Remarks

Continued on next page.

4-6

FUEL

MANUAL INJECTION PUMP (E115AMH, E115AWH)

E 4

4020

Order 9 10 11 12 13 14 15

Job/Part Bolt Cable guide Plastic locking tie Fuel hose Bypass valve Bolt Manual injection pump

Qâ&#x20AC;&#x2122;ty 1 1 12 6 1 2 1

Remarks

Not reusable

For installation, reverse the removal procedure.

4-7

FUEL

MANUAL INJECTION PUMP (E115AMH, E115AWH)

INSPECTING THE BYPASS VALVE 1. Inspect: • Bypass valve Cracks/damage → Replace. 2. Inspect: • Bypass valve operation Air leaks → Replace. Inspecting steps (1) Install the Mity vac onto the bypass valve as shown.

4032

Mity vac YB-35956 / 90890-06756 (2) Apply the pressure with the Mity vac. NOTE: Make sure no air comes out of the opposite side of the bypass valve at the “OFF” position a.

INSPECTING THE MANUAL INJECTION PUMP 1. Inspect: • Manual injection pump Cracks/damage/leaks → Replace. 2. Inspect: • Diaphragm operation • Inlet valve/outlet valve operation Pressure cannot be maintained and does not return gradually to the atmospheric pressure → Replace.

4-8

FUEL

MANUAL INJECTION PUMP (E115AMH, E115AWH)

Inspecting steps NOTE: Do not overpressurize the manual injection pump. Excessive pressure may cause air to leak out. (1) Install the Mity vac onto the manual injection pump as shown. Mity vac YB-35956 / 90890-06756

4034

(2) Block outlet valves and apply the specified pressure with the Mity vac. Pump pressure 50 kPa (0.5 kg/cm2, 7.1 psi)

(3) Remove your fingers to open the outlet valves.

4036

4-9

FUEL

FUEL PUMP

REMOVING/INSTALLING THE FUEL PUMP

4040

Order 1 2 3 4 5 6

Job/Part Plastic locking tie Fuel hose Fuel hose Bolt Fuel pump Gasket

Qâ&#x20AC;&#x2122;ty 7 1 3 2 1 1

4-10

Remarks Not reusable (fuel filter-to-fuel pump) (fuel pump-to-carburetor)

Not reusable For installation, reverse the removal procedure.

FUEL

FUEL PUMP

E 4

DISASSEMBLING/ASSEMBLING THE FUEL PUMP

4220

Order 1 2 3 4 5 6 7

Job/Part Screw Diaphragm body Diaphragm Gasket Fuel pump base Gasket Diaphragm

Qâ&#x20AC;&#x2122;ty 3 1 1 1 1 1 1

Remarks

Not reusable Not reusable Continued on next page.

4-11

FUEL

FUEL PUMP

E 4

4220

Order 8 9 10 11 12 13

Job/Part Spring seat Spring Screw Fuel pump valve Nut Fuel pump body

Qâ&#x20AC;&#x2122;ty 1 1 4 4 4 1

Remarks

For assembly, reverse the disassembly procedure.

4-12

FUEL

FUEL PUMP

INSPECTING THE FUEL PUMP 1. Inspect: • Diaphragm • Fuel pump valves Damage → Replace. 2. Inspect: • Fuel pump Reverse air flow → Replace. Inspecting steps NOTE: Do not overpressurize the fuel pump. Excessive pressure may cause air to leak out. (1) Install the Mity vac onto the fuel pump as shown. Mity vac YB-35956 / 90890-06756 (2) Apply the specified pressure with the Mity vac. Fuel pump pressure a 50 kPa (0.5 kg/cm2, 7.1 psi) Fuel pump negative pressure b 30 kPa (0.3 kg/cm2, 4.3 psi)

4240

NOTE: • Make sure no air comes out of the opposite side of the fuel pump. • To eliminate any gaps between the fuel pump valves and the fuel pump body, and to ensure a better seal, make sure the inside of the fuel pump is wet (i.e., with gas).

4-13

FUEL

OIL TANK

REMOVING/INSTALLING THE OIL TANK

4060

Order Job/Part 1 Oil level sensor coupler and connector 2 Oil level sensor 3 Oil strainer 4 Washer 5 Oil tank air vent hose 6 Plastic locking tie 7 Oil hose

Qâ&#x20AC;&#x2122;ty 2 1 1 1 1 1 1

4-14

Remarks

(oil tank-to-intake silencer) Not reusable (sub oil tank-to-oil tank) Continued on next page.

FUEL

OIL TANK

E 4

4060

Order 8 9 10 11 12 13

Job/Part Bolt Collar Grommet Oil tank Plastic locking tie Oil hose

Qâ&#x20AC;&#x2122;ty 3 3 3 1 1 1

4-15

Remarks

Not reusable (oil tank-to-oil pump) For installation, reverse the removal procedure.

FUEL

CARBURETOR

REMOVING/INSTALLING THE CARBURETOR (OIL INJECTION MODELS)

4070

Order 1 2 3 4 5 6 7 8 9

Job/Part Oil tank air vent hose Intake manifold air vent hose O-ring Fuel enrichment valve connector Bolt Fuel enrichment valve Screw Intake silencer Rubber gasket

Qâ&#x20AC;&#x2122;ty 1 1 1 2 2 1 8 1 2

Remarks (intake silencer-to-oil tank) (intake silencer-to-intake manifold)

Continued on next page.

4-16

FUEL

CARBURETOR

E 4

4070

Order 10 11 12 13 14 15 16 17 18

Job/Part Oil pump link rod Choke link rod Fuel enrichment valve link rod Throttle link rod Nut Carburetor #1 Gasket Plastic locking tie Carburetor #2

Qâ&#x20AC;&#x2122;ty 1 1 1 1 8 1 2 2 1

Remarks

Not reusable Not reusable For installation, reverse the removal procedure.

4-17

FUEL

CARBURETOR

E 4

REMOVING/INSTALLING THE CARBURETOR (PRE-MIXED MODELS)

4075

Order 1 2 3 4 5 6 7 8 9 10

Job/Part Intake manifold air vent hose O-ring Fuel enrichment valve connector Bolt Ground lead Fuel enrichment valve Bolt Intake silencer cover Gasket Bolt

Qâ&#x20AC;&#x2122;ty 1 1 1 2 1 1 8 1 1 8

Remarks (intake silencer-to-intake manifold)

Not reusable Continued on next page.

4-18

FUEL

CARBURETOR

E 4

4075

Order 11 12 13 14 15 16 17 18 19 20

Job/Part Intake silencer Gasket Choke link rod Fuel enrichment valve link rod Throttle link rod Nut Carburetor #1 Plastic locking tie Gasket Carburetor #2

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 8 1 2 2 1

Remarks

Not reusable Not reusable For installation, reverse the removal procedure.

4-19

FUEL

CARBURETOR

E 4

DISASSEMBLING/ASSEMBLING THE CARBURETOR

4080

Order 1 2 3 4 5 6 7 8 9

Job/Part Drank bolt Gasket Screw Float chamber Float pin Float Needle valve Clip Gasket

Qâ&#x20AC;&#x2122;ty 2 2 4 1 2 2 2 2 1

Remarks Not reusable

Continued on next page.

4-20

FUEL

CARBURETOR

E 4

4080

Order 10 11 12 13 14 15 16 17 18

Job/Part Main jet Pilot jet plug Pilot jet Screw Carburetor top cover Screw Gasket Screw Gasket

Qâ&#x20AC;&#x2122;ty 2 2 2 1 1 2 2 1 1

Remarks

Continued on next page.

4-21

FUEL

CARBURETOR

E 4

4080

Order 19 20 21 22 23

Job/Part Pilot air jet Screw Carburetor body Throttle stop screw Spring

Qâ&#x20AC;&#x2122;ty 2 2 1 1 1

Remarks

For assembly, reverse the disassembly procedure.

4-22

FUEL

CARBURETOR

DISASSEMBLING THE CARBURETOR NOTE: Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position.

INSPECTING THE CARBURETOR CAUTION: Do not use a steel wire to clean the jets. This may enlarge the jet diameters and seriously affect performance. 1. Inspect: • Carburetor body Cracks/damage → Replace. Contamination → Clean. 2. Inspect: • Main jet • Pilot jet • Pilot air jet Contamination → Clean. 3. Inspect: • Needle valve Grooved wear → Replace. 4. Inspect: • Float Cracks/damage → Replace.

4090

4110

4-23

FUEL

CARBURETOR

ASSEMBLING THE CARBURETOR NOTE: Before assembling the carburetor, make sure to turn the pilot screw the same number of times, as noted before disassembly, from the seated position to the set position. 1. Install: • Needle valve • Float • Float pin

4120

NOTE: • When installing the float into the carburetor, place the needle valve into the needle valve seat. • After installation, make sure that the float operates smoothly.

2. Measure: • Float height a (without the gasket) Out of specification → Adjust the float height by bending the tab 1. Float height 16.0 ± 0.5 mm (0.63 ± 0.02 in) 4130

NOTE: • The float should be resting on the needle valve, but not compressing it. • Take measurements at the end of the float, opposite the side it pivots on.

4-24

FUEL

OIL PUMP

REMOVING/INSTALLING THE OIL PUMP

4160

Order 1 2 3 4 5 6

Job/Part Clip Washer Oil pump link rod Oil hose Bolt Oil pump

Qâ&#x20AC;&#x2122;ty 1 1 1 1 2 1

Remarks

(oil tank-to-oil pump)

Continued on next page.

4-25

FUEL

OIL PUMP

E 4

4160

Order 7 8 9 10 11 12 13

Job/Part Oil pump drive gear Metal plate O-ring O-ring Clip Oil delivery hose Check valve

Qâ&#x20AC;&#x2122;ty 1 1 1 1 16 8 4

Remarks

(oil pump-to-intake manifold) For installation, reverse the removal procedure.

4-26

FUEL

OIL PUMP

INSPECTING THE CHECK VALVE Inspect: â&#x20AC;˘ Check valve operation Damage/reverse air flow â&#x2020;&#x2019; Replace. Inspecting steps NOTE: Do not overpressurize the check valve. Excessive pressure may cause air to leak out. (1) Install the Mity vac onto the check valve as shown. Mity vac YB-35956 / 90890-06756 (2) Apply the specified pressure with the Mity vac.

4230

Check valve pressure 80 kPa (0.8 kg/cm2, 11.4 psi) NOTE: Make sure no air comes out of the opposite side of the check valve.

4-27

POWR

CHAPTER 5 POWER UNIT RECOIL STARTER........................................................................................... 5-1 REMOVING/INSTALLING THE RECOIL STARTER ................................. 5-1 DISASSEMBLING/ASSEMBLING THE RECOIL STARTER .................... 5-3 REMOVING THE SHEAVE DRUM ........................................................... 5-7 REMOVING THE SPIRAL SPRING........................................................... 5-8 INSTALLING THE STARTER ROPE ......................................................... 5-8 INSTALLING THE SHEAVE DRUM ......................................................... 5-8 INSPECTING THE RECOIL STARTER...................................................... 5-9 FLYWHEEL MAGNET ASSEMBLY .............................................................. 5-10 REMOVING/INSTALLING THE FLYWHEEL MAGNET ASSEMBLY............................................................................................ 5-10 REMOVING THE FLYWHEEL MAGNET ASSEMBLY ........................... 5-11 INSTALLING THE FLYWHEEL MAGNET ASSEMBLY ......................... 5-12 POWER UNIT ................................................................................................ 5-13 DISCONNECTING/CONNECTING THE LEADS .................................... 5-13 DISCONNECTING/CONNECTING THE HOSES.................................... 5-14 REMOVING/INSTALLING THE POWER UNIT ...................................... 5-16 STATOR ASSEMBLY.................................................................................... 5-18 REMOVING/INSTALLING THE STATOR ASSEMBLY (OIL INJECTION EXCEPT FOR 115BETO MODELS) ........................... 5-18 REMOVING/INSTALLING THE STATOR ASSEMBLY (PRE-MIXED AND 115BETO MODELS) ............................................... 5-20 CDI UNIT ....................................................................................................... 5-22 REMOVING/INSTALLING THE CDI UNIT ASSEMBLY......................... 5-22 REMOVING/INSTALLING THE CDI UNIT ............................................. 5-23 RECTIFIER/REGULATOR ............................................................................. 5-25 REMOVING/INSTALLING THE RECTIFIER/REGULATOR (OIL INJECTION EXCEPT FOR 115BETO MODELS) ........................... 5-25 REMOVING/INSTALLING THE RECTIFIER/REGULATOR (PRE-MIXED AND 115BETO MODELS) ............................................... 5-26 RELAY ASSEMBLY AND STARTER MOTOR.............................................. 5-27 REMOVING/INSTALLING THE RELAY ASSEMBLY AND STARTER MOTOR................................................................................. 5-27 CONTROL UNIT............................................................................................ 5-29 REMOVING/INSTALLING THE CONTROL UNIT .................................. 5-29 INSTALLING THE CONTROL UNIT....................................................... 5-31

POWR

INTAKE MANIFOLD...................................................................................... 5-32 REMOVING/INSTALLING THE INATAKE MANIFOLD ......................... 5-32 REED VALVES .............................................................................................. 5-34 REMOVING/INSTALLING THE REED VALVES..................................... 5-34 INSPECTING THE REED VALVE ASSEMBLY ....................................... 5-35 CYLINDER HEADS........................................................................................ 5-36 REMOVING/INSTALLING THE CYLINDER HEADS .............................. 5-36 INSPECTING THE THERMOSTATS ...................................................... 5-38 INSPECTING THE CYLINDER HEADS................................................... 5-38 EXHAUST COVERS...................................................................................... 5-40 REMOVING/INSTALLING THE EXHAUST COVERS ............................ 5-40 INSPECTING THE PRESSURE CONTROL VALVE................................ 5-42 CRANKCASE................................................................................................. 5-43 REMOVING/INSTALLING THE CRANKCASE ....................................... 5-43 ASSEMBLING THE OIL SEAL HOUSING ............................................. 5-45 INSTALLING THE CRANKCASE............................................................ 5-45 CYLINDER BODY ASSEMBLY ..................................................................... 5-46 DISASSEMBLING/ASSEMBLING THE CYLINDER BODY ASSEMBLY............................................................................................ 5-46 DISASSEMBLING/ASSEMBLING THE PISTON AND CONNECTING ROD ASSEMBLIES....................................................... 5-49 DISASSEMBLING/ASSEMBLING THE CRANKSHAFT ASSEMBLY............................................................................................ 5-50 DISASSEMBLING THE UPPER BEARING HOUSING .......................... 5-51 REMOVING THE BEARING AND OIL PUMP DRIVE GEAR.................. 5-51 INSPECTING THE CYLINDER BODY..................................................... 5-52 INSPECTING THE PISTONS .................................................................. 5-53 CALCULATING THE PISTON-TO-CYLINDER CLEARANCE................. 5-53 INSPECTING THE PISTON PINS AND SMALL-END BEARINGS ........ 5-54 INSPECTING THE PISTON RINGS ........................................................ 5-54 INSPECTING THE OIL PUMP DRIVEN GEAR ....................................... 5-55 INSPECTING THE LABYRINTH RINGS ................................................. 5-56 INSPECTING THE CRANKSHAFT ......................................................... 5-56 INSTALLING THE OIL PUMP DRIVE GEAR .......................................... 5-57 INSTALLING THE BEARING.................................................................. 5-57 INSTALLING THE PISTON RINGS AND PISTON................................. 5-57 ASSEMBLING THE UPPER BEARING HOUSING ................................ 5-58 INSTALLING THE CRANKSHAFT ASSEMBLY..................................... 5-59 INSTALLING THE PISTON AND CONNECTING ROD ASSEMBLIES......................................................................................... 5-59

1 2 3 4 5 6 7 8 9

POWR

RECOIL STARTER

REMOVING/INSTALLING THE RECOIL STARTER

5001

Order 1 2 3 4 5 6 7

Job/Part Cotter pin Washer Bolt Start-in-gear protection wire Bolt Bolt Washer

Qâ&#x20AC;&#x2122;ty 1 1 1 1 2 3 3

Remarks Not reusable

Continued on next page.

5-1

POWR

RECOIL STARTER

5 5

5001

Order 8 9 10 11 12 13 14

Job/Part Recoil starter assembly Collar Grommet Bolt Starter pulley Bolt Recoil starter bracket

Qâ&#x20AC;&#x2122;ty 1 3 6 3 1 3 1

Remarks

For installation, reverse the removal procedure.

5-2

POWR

RECOIL STARTER

5 DISASSEMBLING/ASSEMBLING THE RECOIL STARTER

5002

Order 1 2 3 4 5 6 7 8 9 10

Job/Part Screw Stopper Torsion spring Spring Guide cam Bolt Starter rope guide bracket Collar Grommet Nut

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 2 1 2 2 2

Remarks

Continued on next page.

5-3

POWR

RECOIL STARTER

5 5

5002

Order 11 12 13 14 15 16 17 18 19 20

Job/Part Bolt Stay Collar Grommet Nut Bolt Starter rope guide Starter handle end-piece Starter handle Damper

Qâ&#x20AC;&#x2122;ty 2 1 2 2 2 2 1 1 1 1

Remarks

Continued on next page.

5-4

POWR

RECOIL STARTER

5 5

5002

Order 21 22 23 24 25 26 27 28 29 30

Job/Part Bolt Roller Collar Bolt Roller holder Bolt Thrust washer Drive plate Return spring Drive pawl

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 1 1 1 1

Remarks

Continued on next page.

5-5

POWR

RECOIL STARTER

5 5

5002

Order 31 32 33 34 35 36 37 38 39 40

Job/Part Bushing Drive plate spring Circlip Washer Sheave drum Starter rope Spiral spring Thrust plate Bushing Recoil starter case

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 1 2 1 1

Remarks

For assembly, reverse the disassembly procedure.

5-6

POWR

RECOIL STARTER

REMOVING THE SHEAVE DRUM

1. Turn: • Sheave drum 1 Turn the sheave drum clockwise until the spiral spring is free. NOTE: • Turn the sheave drum so that the cutaway on the outer surface of the sheave drum faces toward the starter handle. • Pass the starter rope through the cutaway a.

5004

2. Remove: • Bolt 1 • Thrust washer 2 • Drive plate 3 • Return spring 4 • Drive pawl 5 • Bushing 6 • Drive plate spring 7 • Circlip 8 • Washer 9

5005

3. Remove: • Sheave drum 1 • Bushing

WARNING When removing the sheave drum, be sure to turn the sheave drum upside down to prevent the spiral spring from popping up at you.

5006

NOTE: Insert a slotted-head screwdriver into the hole a in the sheave drum and push down on the spiral spring so that it releases from the sheave drum.

5-7

POWR

RECOIL STARTER

REMOVING THE SPIRAL SPRING

Remove: • Thrust plate 1 • Spiral spring 2 • Thrust plate 3

WARNING Be careful so that the spiral spring does not pop out when removing it. Remove it by allowing it out one turn of the winding each time.

5007

INSTALLING THE STARTER ROPE

Install: • Starter rope NOTE: • Insert the starter rope through the rope holes and then tie a knot on the end of the rope. • Wind the starter rope 2-1/2 turns around the sheave drum. • Place the starter rope through the cutaway.

INSTALLING THE SHEAVE DRUM

5008

1. Install: • Thrust plate • Spiral spring 1 • Thrust plate • Bushing • Sheave drum 2 NOTE: Position the inner end of the spiral spring on the retainer post a of the sheave drum.

5009

5-8

POWR

RECOIL STARTER

E 2. Install: • Drive plate spring 1 • Washer 2 • Circlip 3

5011

3. Set: • Spiral spring NOTE: Wind the spiral spring three turns counterclockwise with the starter rope.

5012

4. Install: • Bushing 1 • Drive pawl 2 • Return spring 3 • Drive plate 4 • Thrust washer 5 • Bolt 6

5013

INSPECTING THE RECOIL STARTER 5 Inspect: • Recoil starter operation Rough operation → Repair. NOTE: When checking the recoil starter operation, push the start-in-gear protection stopper and pull the recoil starter handle (at the same time).

5014

5-9

POWR

FLYWHEEL MAGNET ASSEMBLY

REMOVING/INSTALLING THE FLYWHEEL MAGNET ASSEMBLY

5010

Order

1 2 3 4 5 6 7 8 9

Job/Part Recoil starter assembly Bolt Flywheel magnet assembly cover Collar Grommet Grommet Flywheel magnet assembly nut Washer Flywheel magnet assembly Woodruff key

Q’ty

Remarks (E115AMH, E115AWH) Refer to “RECOIL STARTER” on page 5-1.

2 1 2 2 2 1 1 1 1 For installation, reverse the removal procedure.

Å Pre-mixed and 115BETO models

5-10

POWR

FLYWHEEL MAGNET ASSEMBLY

REMOVING THE FLYWHEEL MAGNET ASSEMBLY 5

Remove: • Flywheel magnet assembly Removing steps (1) Remove the flywheel magnet assembly nut. 5020

Flywheel magnet assembly holder YB-06139 / 90890-06522

Å For USA and Canada ı Except for USA and Canada

NOTE: The major load should be applied in the direction of the arrows. If the load is not applied as shown, the flywheel magnet assembly holder may easily slip off of the flywheel magnet assembly.

5030

(2) Remove the flywheel magnet assembly. Universal puller YB-06117 / 90890-06521 Å For USA and Canada ı Except for USA and Canada

5040

NOTE: • The major load should be applied in the direction of the arrows. • Apply the load until the flywheel magnet assembly comes off the tapered portion of the crankshaft.

CAUTION: 5050

To prevent damage to the engine or tools, screw in the universal puller set-bolts evenly and completely so that the puller plate is parallel to the flywheel magnet assembly.

5-11

POWR

FLYWHEEL MAGNET ASSEMBLY

INSTALLING THE FLYWHEEL MAGNET ASSEMBLY

Install: • Flywheel magnet assembly nut Flywheel magnet assembly holder YB-06139 / 90890-06522 5060

Å For USA and Canada ı Except for USA and Canada

NOTE: The major load should be applied in the direction of the arrows. If the load is not applied as shown, the flywheel magnet assembly holder may easily slip off of the flywheel magnet assembly. 5070

5-12

Flywheel magnet assembly nut 190 Nm (19 m • kgf, 137 ft • lb)

POWR

POWER UNIT

DISCONNECTING/CONNECTING THE LEADS

5080

Order

1 2 3

Job/Part Battery leads Remote control shift and throttle cables Choke rod Remote control coupler Trim sensor coupler and connector

Qâ&#x20AC;&#x2122;ty

1 1 2

Remarks (from the battery)

(remote control models) (power trim and tilt models) For installation, reverse the removal procedure.

5-13

POWR

POWER UNIT

5 DISCONNECTING/CONNECTING THE HOSES

5090

Order 1 2 3 4 5 6 7 8

Job/Part Bolt Negative battery lead Nut Positive battery lead Pilot water hose Cooling water hose Bolt Metal clamp

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 1 1

Remarks

Continued on next page.

5-14

POWR

POWER UNIT

5 5

5090

Order 9 10 11 12 13 14

Job/Part Ground lead Trailer switch coupler Bolt Cable guide Power trim and tilt lead Power trim and tilt lead

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1

5-15

Remarks (power trim and tilt models)

(blue) (power trim and tilt models) (green) (power trim and tilt models) For installation, reverse the removal procedure.

POWR

POWER UNIT

5 REMOVING/INSTALLING THE POWER UNIT

5100

Order 1 2 3 4 5 6

Job/Part Bolt Bolt Bolt Forward apron Bolt Rear apron

Qâ&#x20AC;&#x2122;ty 2 2 2 1 4 1

Remarks

Continued on next page.

5-16

POWR

POWER UNIT

5 5

5100

Order 7 8 9 10 11 12

Job/Part Nut Bolt Bolt Power unit Gasket Dowel pin

Qâ&#x20AC;&#x2122;ty 2 4 6 1 1 2

Remarks

Not reusable For installation, reverse the removal procedure.

5-17

POWR

STATOR ASSEMBLY

REMOVING/INSTALLING THE STATOR ASSEMBLY (OIL INJECTION EXCEPT FOR 115BETO MODELS)

5110

Order

1 2 3 4 5 6

Job/Part Flywheel magnet assembly Screw CDI unit cover Screw Rectifier/regulator cover Charge coil coupler Lighting coil coupler

Q’ty

Remarks Refer to “FLYWHEEL MAGNET ASSEMBLY” on page 5-10.

4 1 5 1 1 1 Continued on next page.

5-18

POWR

STATOR ASSEMBLY

5 5

5110

Order 7 8 9 10 11 12 13

Job/Part Bolt Stator assembly Pulser coil coupler Screw Pulser coil bushing retainer Pulser coil assembly Pulser coil bushing

Qâ&#x20AC;&#x2122;ty 3 1 1 4 4 1 1

Remarks

For installation, reverse the removal procedure.

5-19

POWR

STATOR ASSEMBLY

5 REMOVING/INSTALLING THE STATOR ASSEMBLY (PRE-MIXED AND 115BETO MODELS)

5115

Order

1 2 3 4 5 6

Job/Part Flywheel magnet assembly Screw CDI unit cover Charge coil coupler Lighting coil connector Bolt Stator assembly

Q’ty

Remarks Refer to “FLYWHEEL MAGNET ASSEMBLY” on page 5-10.

4 1 1 2 3 1 Continued on next page.

5-20

POWR

STATOR ASSEMBLY

5 5

5115

Order 7 8 9 10 11

Job/Part Pulser coil coupler Screw Pulser coil bushing retainer Pulser coil assembly Pulser coil bushing

Qâ&#x20AC;&#x2122;ty 1 4 4 1 1

Remarks

For installation, reverse the removal procedure.

5-21

POWR

CDI UNIT

REMOVING/INSTALLING THE CDI UNIT ASSEMBLY

5120

Order

1 2 3 4 5 6 7 8

Job/Part CDI unit cover Bolt Ground lead Spark plug cap Bolt Ground lead CDI unit coupler Bolt CDI unit assembly

Q’ty

2 2 4 1 2 1 3 1

Remarks Refer to “STATOR ASSEMBLY” on page 5-18.

(pre-mixed and 115BETO models) (pre-mixed and 115BETO models)

For installation, reverse the removal procedure.

5-22

POWR

CDI UNIT

5 REMOVING/INSTALLING THE CDI UNIT

5130

Order 1 2 3 4 5 6

Job/Part Ignition coil connector Bolt Ignition coil Ground lead Screw Ground lead

Q’ty 4 4 4 4 3 1

Remarks

Continued on next page. Å Pre-mixed and 115BETO models

5-23

POWR

CDI UNIT

5 5

5130

Order 7 8 9 10 11

Job/Part Screw CDI unit Collar Grommet CDI unit case

Q’ty 2 1 3 3 1

Remarks

For installation, reverse the removal procedure. Å Pre-mixed and 115BETO models

5-24

POWR

RECTIFIER/REGULATOR

REMOVING/INSTALLING THE RECTIFIER/REGULATOR (OIL INJECTION EXCEPT FOR 115BETO MODELS)

5140

Order

Job/Part Rectifier/regulator cover

Q’ty

Lighting coil coupler 1 2 3 4 5 6 7

Rectifier/regulator coupler Bolt Ground lead Bolt Rectifier/regulator Bolt Rectifier/regulator bracket

Remarks Refer to “STATOR ASSEMBLY” on page 5-18. Refer to “STATOR ASSEMBLY” on page 5-18.

1 1 2 2 1 3 1 For installation, reverse the removal procedure. 5-25

POWR

RECTIFIER/REGULATOR

5 REMOVING/INSTALLING THE RECTIFIER/REGULATOR (PRE-MIXED AND 115BETO MODELS)

5145

Order

1 2 3 4 5 6 7

Job/Part Lighting coil connector Bolt Ground lead Bolt Rectifier/regulator cover Collar Rectifier/regulator connector Rectifier/regulator

Q’ty

Remarks Refer to “STATOR ASSEMBLY” on page 5-18.

1 2 2 1 2 2 1 For installation, reverse the removal procedure.

5-26

POWR

RELAY ASSEMBLY AND STARTER MOTOR

REMOVING/INSTALLING THE RELAY ASSEMBLY AND STARTER MOTOR

5150

Order

Job/Part Negative battery lead Positive battery lead Power trim and tilt leads

Q’ty

Remarks Refer to “POWER UNIT” on page 5-13. Refer to “POWER UNIT” on page 5-13. (power trim and tilt models) Refer to “POWER UNIT” on page 5-13. (oil injection models) Refer to “OIL TANK” on page 4-14. (oil injection models)

2 1

(oil injection models) (oil injection models)

(oil injection models) Continued on next page.

Oil tank 1 2 3 4

Oil pump control unit/emergency switch coupler Bolt Oil pump control unit/emergency switch Collar

5-27

POWR

RELAY ASSEMBLY AND STARTER MOTOR

5 5

5150

Order 5 6 7 8 9 10 11 12 13 14 15

Job/Part Grommet Plastic locking tie Plastic tube Starter motor lead Relay assembly lead Bolt Ground lead Ground lead Relay assembly Bolt Starter motor

Qâ&#x20AC;&#x2122;ty 2 1 1 1 3 2 1 1 1 3 1

Remarks (oil injection models)

(oil injection except for 115BETO models)

For installation, reverse the removal procedure. 5-28

POWR

CONTROL UNIT

REMOVING/INSTALLING THE CONTROL UNIT

5160

Order Job/Part 1 Throttle cam control link 2 Bolt 3 Accelerator control lever assembly 4 Nylon washer 5 Washer 6 Spacer 7 Bushing 8 Throttle lever

Qâ&#x20AC;&#x2122;ty 2 1 1

Remarks

1 1 1 1 1 Continued on next page.

5-29

POWR

CONTROL UNIT

5 5

5160

Order 9 10 11 12 13 14 15

Job/Part Spring Bushing Accelerator control lever Bolt Collar Wave washer Throttle cam

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 1

Remarks

For installation, reverse the removal procedure.

5-30

POWR

CONTROL UNIT

INSTALLING THE CONTROL UNIT

1. Install: • Bushing 1 • Spring 2 NOTE: Mesh the spring hook with the slit in the accelerator control lever. 5165

2. Install: • Throttle lever 1 NOTE: • Mesh the throttle lever hook with the spring hook. • Turn the throttle lever clockwise and hook the projection a on the throttle lever with the notch b in the accelerator control lever.

5166

5167

3. Adjust: • Ignition timing Refer to “CONTROL SYSTEM” on page 3-4.

5-31

POWR

INTAKE MANIFOLD

REMOVING/INSTALLING THE INATAKE MANIFOLD

5180

Order

1 2 3 4 5

Job/Part Carburetor assembly Fuel pump Screw Timing plate Bolt Hose clamp Intake manifold air vent hose

Q’ty

Remarks Refer to “CARBURETOR” on page 4-16. Refer to “FUEL PUMP” on page 4-10.

1 1 1 1 1 Continued on next page.

5-32

POWR

INTAKE MANIFOLD

5 5

5180

Order 6 7 8 9 10

Job/Part Oil hose Recirculation hose Bolt Intake manifold Gasket

Qâ&#x20AC;&#x2122;ty 4 8 12 1 1

5-33

Remarks (oil injection models)

Not reusable For installation, reverse the removal procedure.

POWR

REED VALVES

REMOVING/INSTALLING THE REED VALVES

5190

Order

Job/Part Intake manifold

Q’ty

1 2 3 4 5 6 7

Screw Reed valve assembly Gasket Screw Reed valve stopper Reed valve Reed valve seat

8 4 4 8 4 4 1

Remarks Refer to “INTAKE MANIFOLD” on page 5-32.

Not reusable

For installation, reverse the removal procedure.

5-34

POWR

REED VALVES

INSPECTING THE REED VALVE ASSEMBLY 1. Inspect: • Reed valve Cracks/damage → Replace.

2. Measure: • Warpage limit a Out of specification → Replace. Warpage limit 0.2 mm (0.008 in)

5220

3. Measure: • Reed valve stopper height a Out of specification → Replace. Reed valve stopper height 6.5 ± 0.3 mm (0.26 ± 0.01 in)

5230

5-35

POWR

CYLINDER HEADS

REMOVING/INSTALLING THE CYLINDER HEADS

5250

Order 1 2 3 4 5 6 7 8

Job/Part Spark plug cap Spark plug Bolt Thermostat cover Gasket Thermostat Bolt Clamp Cylinder head cover

Q’ty 4 8 2 2 2 24 1 2

Remarks Refer to “CDI UNIT” on page 5-22.

Not reusable

(starboard side) Continued on next page.

5-36

POWR

CYLINDER HEADS

5 5

5250

Order 9 10 11 12 13 14 15

Job/Part Gasket Thermo switch Bolt Ground lead Bolt Cylinder head Gasket

Qâ&#x20AC;&#x2122;ty 2 2 2 2 20 2 2

5-37

Remarks Not reusable

Not reusable For installation, reverse the removal procedure.

POWR

CYLINDER HEADS

INSPECTING THE THERMOSTATS

1. Inspect: • Thermostat Damage/valve does not open → Replace. 2. Measure: • Thermostat opening temperature • Valve lift a Out of specification → Replace.

5260

Water temperature

Valve lift

Below 48 - 52 ˚C (118 - 126 ˚F)

0 mm (0 in)

Above 60 ˚C (140 ˚F)

Min. 3 mm (0.12 in)

Measuring steps (1) Suspend the thermostat in a container filled with water. (2) Place a thermometer in the water. (3) Slowly heat the water. (4) While stirring the water, check that the thermostat opens at the specified temperature.

INSPECTING THE CYLINDER HEADS 5 1. Inspect: • Combustion chamber Carbon deposits → Clean. • Water jacket Mineral deposits/rust → Clean.

CAUTION: 5265

Do not scratch the contacting surfaces of the cylinder head and cylinder head cover.

5-38

POWR

CYLINDER HEADS

E 2. Measure: â&#x20AC;˘ Cylinder head warpage (with a straightedge and thickness gauge) Out of specification â&#x2020;&#x2019; Resurface or replace. Warpage limit 0.1 mm (0.004 in)

5270

Resurfacing steps (1) Place a 400 - 600 grit wet sandpaper on the surface plate. (2) Resurface the cylinder head by moving it in a figure-eight motion along the sandpaper. NOTE: Rotate the cylinder head several times to ensure an even surface.

5280

5290

5-39

POWR

EXHAUST COVERS

REMOVING/INSTALLING THE EXHAUST COVERS

5300

Order

1 2 3 4 5

Job/Part Pilot water hose Cooling water hose CDI unit assembly Bolt Pressure control valve cover Gasket Spring Pressure control valve

Q’ty

2 1 1 1 1

Remarks Refer to “POWER UNIT” on page 5-13. Refer to “POWER UNIT” on page 5-13. Refer to “CDI UNIT” on page 5-22.

Not reusable

Continued on next page.

5-40

POWR

EXHAUST COVERS

5 5

5300

Order 6 7 8 9 10 11

Job/Part Pressure control valve seat Bolt Exhaust outer cover Gasket Exhaust inner cover Gasket

Qâ&#x20AC;&#x2122;ty 1 23 1 1 1 1

5-41

Remarks

Not reusable Not reusable For installation, reverse the removal procedure.

POWR

EXHAUST COVERS

INSPECTING THE PRESSURE CONTROL VALVE

Inspect: • Pressure control valve seat 1 • Pressure control valve 2 • Pressure control valve cover 3 Cracks/damage → Replace any defective parts. • Spring 4 Damage/wear → Replace.

5310

5-42

POWR

CRANKCASE

REMOVING/INSTALLING THE CRANKCASE

5320

Order

Job/Part Flywheel magnet assembly

Q’ty

Power unit Pulser coil bushing Intake manifold 1 2 3

Bolt Bolt Bolt

Remarks Refer to “FLYWHEEL MAGNET ASSEMBLY” on page 5-10. Refer to “POWER UNIT” on page 5-13. Refer to “STATOR ASSEMBLY” on page 5-18. Refer to “INTAKE MANIFOLD” on page 5-32.

8 6 4 Continued on next page.

5-43

POWR

CRANKCASE

5 5

5320

Order 4 5 6 7 8 9

Job/Part Bolt Crankcase Oil seal housing O-ring Oil seal Dowel pin

Qâ&#x20AC;&#x2122;ty 4 1 1 1 2 2

Remarks

For installation, reverse the removal procedure.

5-44

POWR

CRANKCASE

ASSEMBLING THE OIL SEAL HOUSING

Install: • Oil seal Bearing/oil seal attachment .... 1 YB-06195 / 90890-06637 90890-06631 Driver rod .................................. 2 YB-06071 / 90890-06606

5330

Å For USA and Canada ı Except for USA and Canada

5340

INSTALLING THE CRANKCASE

Apply: • Gasket Maker® (onto the crankcase mating surfaces) NOTE: • Clean the mating surfaces of the crankcase and cylinder body before applying Gasket Maker®. • Do not allow any sealant to overflow from the mating surfaces.

5350

5-45

POWR

CYLINDER BODY ASSEMBLY

DISASSEMBLING/ASSEMBLING THE CYLINDER BODY ASSEMBLY

5360

Order

1 2 3 4 5 6 7

Job/Part Cylinder heads Crankcase Upper bearing housing Oil seal O-ring Needle bearing Connecting rod bolt Connecting rod cap Big-end bearing

Q’ty

Remarks Refer to “CYLINDER HEADS” on page 5-36. Refer to “CRANKCASE” on page 5-43.

1 1 2 1 8 4 4 Continued on next page.

5-46

POWR

CYLINDER BODY ASSEMBLY

5 5

5360

Order 8 9 10 11 12 13 14 15 16

Job/Part Piston/connecting rod assembly Crankshaft assembly Clip Main journal bearing Screw Anode Bolt Lead holder Cylinder cover

Qâ&#x20AC;&#x2122;ty 4 1 1 1 4 4 7 1 1

Remarks

Continued on next page.

5-47

POWR

CYLINDER BODY ASSEMBLY

5 5

5360

Order 17 18 19 20 21 22 23

Job/Part Gasket Bolt Engine hanger Bolt Damper bracket Oil pump driven gear Cylinder body

Qâ&#x20AC;&#x2122;ty 1 2 1 4 2 1 1

Remarks Not reusable

(oil injection models) For assembly, reverse the disassembly procedure.

5-48

POWR

CYLINDER BODY ASSEMBLY

5 DISASSEMBLING/ASSEMBLING THE PISTON AND CONNECTING ROD ASSEMBLIES

5370

Order 1 2 3 4 5 6 7

Job/Part Piston pin clip Piston pin Piston Washer Small-end bearing Piston ring Connecting rod

Qâ&#x20AC;&#x2122;ty 8 4 4 8 4 8 4

Remarks Not reusable

For assembly, reverse the disassembly procedure.

5-49

POWR

CYLINDER BODY ASSEMBLY

5 DISASSEMBLING/ASSEMBLING THE CRANKSHAFT ASSEMBLY

5600

Order 1 2 3 4 5

Job/Part Labyrinth ring Circlip Ball bearing Oil pump drive gear Crankshaft

Qâ&#x20AC;&#x2122;ty 6 1 1 1 1

Remarks

(oil injection models) For assembly, reverse the disassembly procedure.

5-50

POWR

CYLINDER BODY ASSEMBLY

DISASSEMBLING THE UPPER BEARING HOUSING

Remove: • Needle bearing Needle bearing attachment..... 1 YB-06205 / 90890-06663 Driver rod .................................. 2 90890-06606 5390

Å For USA and Canada ı Except for USA and Canada

5400

REMOVING THE BEARING AND OIL PUMP DRIVE GEAR 5 Remove: • Bearing • Oil pump drive gear Bearing separator ..................... YB-06219 / 90890-06534 Guide plate stand ..................... 90890-06538 Guide plate................................ 90890-06501 Bearing puller............................ 90890-06535

5610

5-51

1 2 3 4

POWR

CYLINDER BODY ASSEMBLY

INSPECTING THE CYLINDER BODY 5 1. Inspect: • Cylinder sleeves Cracks/score marks → Replace. • Cylinder body water jacket Mineral deposits/rust → Clean.

CAUTION: Do not scratch the contacting surfaces of the crankcase and cylinder head. 2. Inspect: • Exhaust passages Cracks/damage → Replace. Carbon deposits → Clean.

CAUTION: Do not scratch the contacting surfaces of the cylinder and exhaust inner cover. 3. Measure: • Cylinder bore diameter “D” (with a cylinder bore gauge) Out of specification → Replace. NOTE: Measure the cylinder bore diameter at three positions for both D1 and D2. Then, average the measurements.

5410

Standard

5420

Wear limit

Cylinder 90.00 - 90.02 mm bore diame(3.543 - 3.544 in) ter “D”

90.1 mm (3.55 in)

Taper limit T

—

0.08 mm (0.003 in)

Out of round limit R

—

0.05 mm (0.002 in)

T = (maximum D1 or D2) – (minimum D5 or D6) R = Maximum (D1 – D2) or (D3 – D4) or (D5 – D6) A: 10 mm (0.4 in) below the top of the cylinder B: 5 mm (0.2 in) above the exhaust port C: 5 mm (0.2 in) below the scavenging port

5430

5-52

POWR

CYLINDER BODY ASSEMBLY

INSPECTING THE PISTONS

Measure: • Piston diameter (with a micrometer) Out of specification → Replace.

5440

Standard

Measuring point “H”

Piston diameter

10 mm (0.4 in)

89.920 - 89.935 mm (3.5402 - 3.5407 in)

Oversize piston diameter 1st oversize* 90.25 mm (3.553 in) 2nd oversize 90.50 mm (3.563 in) *: Except for USA NOTE: When measuring the piston diameter, position the micrometer in relation to the piston pin hole as shown.

CALCULATING THE PISTON-TOCYLINDER CLEARANCE

Calculate: • Piston-to-cylinder clearance a Out of specification → Replace the piston and piston rings, the cylinder or both. Piston-tocylinder clearance

5450

Cylinder bore diameter

–

Piston diameter

Piston-to-cylinder clearance 0.080 - 0.085 mm (0.0031 - 0.0033 in)

5-53

POWR

CYLINDER BODY ASSEMBLY

INSPECTING THE PISTON PINS AND SMALL-END BEARINGS 5 1. Inspect: • Piston pin • Small-end bearing Heat discoloration → Replace. Damage/scratches → Replace.

2. Measure: • Piston pin diameter (with a micrometer) Out of specification → Replace. Piston pin diameter Except for E115A: 23.065 - 23.070 mm (0.9081 - 0.9083 in) For 115A: 21.495 - 21.500 mm (0.8463 - 0.8465 in)

5460

3. Measure: • Piston pin boss diameter (with a micrometer) Out of specification → Replace. Piston pin boss diameter Except for E115A: 23.074 - 23.085 mm (0.9084 - 0.9089 in) For 115A: 21.504 - 21.510 mm (0.8466 - 0.8468 in)

5470

INSPECTING THE PISTON RINGS

NOTE: • Before inspecting the piston rings, be sure to inspect the cylinder body. • Piston rings should always be replaced as a set (per piston).

5-54

POWR

CYLINDER BODY ASSEMBLY

1. Measure: • Piston ring end gap a (with a thickness gauge) Out of specification → Replace. Piston ring end gap 0.30 - 0.40 mm (0.012 - 0.016 in) Piston ring end gap limit 0.60 mm (0.024 in) Measuring point “H” 20 mm (0.8 in)

5480

NOTE: Push the piston ring into the cylinder with the piston crown.

5490

2. Measure: • Piston ring side clearance b (with a thickness gauge) Out of specification → Replace the piston and piston rings as a set. Piston ring side clearance 0.02 - 0.06 mm (0.001 - 0.002 in)

5500

NOTE: When measuring the piston ring side clearance, the outside of the piston ring should be flush with the piston wall.

INSPECTING THE OIL PUMP DRIVEN GEAR 5 Inspect: • Oil pump driven gear Cracks/pitting/wear → Replace.

5510

5-55

POWR

CYLINDER BODY ASSEMBLY

INSPECTING THE LABYRINTH RINGS5 1. Inspect: • Labyrinth ring 1 Cracks/damage/wear → Replace. 2. Measure: • Labyrinth ring wear a or b + c Out of specification → Replace. Labyrinth ring wear limit 0.10 mm (0.004 in)

5620

INSPECTING THE CRANKSHAFT

1. Measure: • Crankshaft runout (with V-blocks and a dial gauge) Out of specification → Replace. Runout limit 0.05 mm (0.002 in)

5630

2. Measure: • Small-end axial play Out of specification → Replace the connecting rod. Small-end axial play limit 2.0 mm (0.08 in) 5640

3. Measure: • Big-end side clearance Out of specification → Replace the connecting rod. Big-end side clearance 0.12 - 0.26 mm (0.005 - 0.010 in) 5650

4. Inspect: • Crankshaft bearing Pitting/rumbling → Replace. 5. Inspect: • Oil pump drive gear Cracks/pitting/wear → Replace.

5-56

POWR

CYLINDER BODY ASSEMBLY

INSTALLING THE OIL PUMP DRIVE GEAR 5 Install: • Oil pump drive gear Bearing separator ..................... 1 YB-06219 / 90890-06534 Bearing/oil seal attachment .... 2 90890-06661 90890-06622

5660

INSTALLING THE BEARING

Install: • Bearing Bearing separator ..................... 1 YB-06219 / 90890-06534 Bearing/oil seal attachment .... 2 90890-06662 90890-06622 5670

INSTALLING THE PISTON RINGS AND PISTON

1. Install: • 2nd piston ring • Top piston ring

CAUTION: • Align each piston ring end gap with its respective locating pin. • After installing the piston rings, check that they move smoothly.

5520

5-57

POWR

CYLINDER BODY ASSEMBLY

2. Install: • Small-end bearing 1 • Washers 2 • Piston 3 • Piston pin 4 • Piston pin clips 5

CAUTION: 5530

The washers must be installed with their convex sides facing towards the piston.

NOTE: The embossed YAMAHA mark a on the connecting rod must face the same direction as the “UP” mark on the piston.

ASSEMBLING THE UPPER BEARING HOUSING 5

1. Install: • Needle bearing Needle bearing attachment..... 1 YB-06205 / 90890-06663 Driver rod .................................. 2 90890-06606 5540

Å For USA and Canada ı Except for USA and Canada

5550

2. Install: • Oil seal Bearing/oil seal attachment .... 1 YB-06195 / 90890-06624 Driver rod .................................. 2 YB-06071 / 90890-06606

5560

5-58

POWR

CYLINDER BODY ASSEMBLY

INSTALLING THE CRANKSHAFT ASSEMBLY

Install: • Cylinder body • Crankshaft assembly NOTE: • Align the crankshaft labyrinth ring end gaps with their respective locating pins. • Install the bearing locating pins into the cylinder body.

5570

INSTALLING THE PISTON AND CONNECTING ROD ASSEMBLIES

Install: • Piston and connecting rod assembly Piston ring compressor YU-33294 / 90890-06530 5580

NOTE: • Before installing the piston and connecting rod assemblies, lubricate the cylinder walls with 2-stroke outboard motor oil. • Reinstall the piston and connecting rod assemblies in their original cylinders. • Install the piston and connecting rod assemblies with the “S” mark in the starboard side cylinders, and those with the “P” mark in the port side cylinders. • The “UP” mark on the piston crown must face towards the flywheel.

5590

5-59

LOWR

CHAPTER 6 LOWER UNIT LOWER UNIT (REGULAR ROTATION MODELS) ......................................... 6-1 REMOVING/INSTALLING THE LOWER UNIT (EXCEPT FOR B115)...... 6-1 REMOVING/INSTALLING THE LOWER UNIT (FOR B115) .................... 6-3 REMOVING THE PROPELLER ................................................................. 6-4 INSPECTING THE PROPELLER ............................................................... 6-4 INSTALLING THE PROPELLER................................................................ 6-4 WATER PUMP (REGULAR ROTATION MODELS)........................................ 6-5 REMOVING/INSTALLING THE WATER PUMP (EXCEPT FOR B115).... 6-5 REMOVING/INSTALLING THE WATER PUMP (FOR B115)................... 6-7 INSPECTING THE IMPELLER HOUSING ................................................ 6-9 INSPECTING THE IMPELLER AND IMPELLER HOUSING CUP ............ 6-9 INSPECTING THE WOODRUFF KEY....................................................... 6-9 INSTALLING THE IMPELLER AND IMPELLER HOUSING ..................... 6-9 SHIFT ROD ASSEMBLY (REGULAR ROTATION MODELS) ...................... 6-10 REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY (EXCEPT FOR B115).............................................................................. 6-10 REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY (FOR B115) . 6-11 REMOVING THE SHIFT ROD ASSEMBLY (EXCEPT FOR B115) ......... 6-12 REMOVING THE SHIFT ROD ASSEMBLY (FOR B115) ........................ 6-12 PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS) .............................................................. 6-13 REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY............................................................................................ 6-13 DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING .............................................................................................. 6-15 DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASSEMBLY............................................................................................ 6-16 REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY............ 6-17 DISASSEMBLING THE PROPELLER SHAFT HOUSING ...................... 6-17 INSPECTING THE REVERSE GEAR....................................................... 6-18 INSPECTING THE BEARING.................................................................. 6-18 INSPECTING THE PROPELLER SHAFT HOUSING .............................. 6-18 INSPECTING THE DOG CLUTCH .......................................................... 6-19 INSPECTING THE PROPELLER SHAFT................................................. 6-19 ASSEMBLING THE PROPELLER SHAFT HOUSING ............................ 6-19 ASSEMBLING THE REVERSE GEAR .................................................... 6-19 INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY.......... 6-20

LOWR DRIVE SHAFT (REGULAR ROTATION MODELS)....................................... 6-21 REMOVING/INSTALLING THE DRIVE SHAFT...................................... 6-21 REMOVING THE DRIVE SHAFT ............................................................ 6-23 DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY ........... 6-23 DISASSEMBLING THE FORWARD GEAR ASSEMBLY ....................... 6-23 INSPECTING THE PINION ..................................................................... 6-24 INSPECTING THE DRIVE SHAFT .......................................................... 6-24 INSPECTING THE DRIVE SHAFT HOUSING ........................................ 6-24 INSPECTING THE BEARINGS ............................................................... 6-24 ASSEMBLING THE FORWARD GEAR ASSEMBLY ............................. 6-24 ASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY ................. 6-25 INSTALLING THE DRIVE SHAFT........................................................... 6-26 LOWER CASE ASSEMBLY (REGULAR ROTATION MODELS).................. 6-27 DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY (EXCEPT FOR B115).............................................................................. 6-27 DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY (FOR B115)............................................................................................. 6-28 DISASSEMBLING THE LOWER CASE ASSEMBLY ............................. 6-29 INSPECTING THE DRIVE SHAFT SLEEVE ............................................ 6-29 INSPECTING THE NEEDLE BEARING................................................... 6-29 ASSEMBLING THE LOWER CASE ASSEMBLY ................................... 6-29 LOWER UNIT (COUNTER ROTATION MODELS)....................................... 6-31 REMOVING/INSTALLING THE LOWER UNIT ...................................... 6-31 REMOVING THE PROPELLER ............................................................... 6-33 INSPECTING THE PROPELLER ............................................................. 6-33 INSTALLING THE PROPELLER.............................................................. 6-33 WATER PUMP (COUNTER ROTATION MODELS) ..................................... 6-34 REMOVING/INSTALLING THE WATER PUMP..................................... 6-34 INSPECTING THE IMPELLER HOUSING .............................................. 6-36 INSPECTING THE IMPELLER AND IMPELLER HOUSING CUP .......... 6-36 INSPECTING THE WOODRUFF KEY..................................................... 6-36 INSTALLING THE IMPELLER AND IMPELLER HOUSING ................... 6-36 SHIFT ROD ASSEMBLY (COUNTER ROTATION MODELS)...................... 6-37 REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY ..................... 6-37 REMOVING THE SHIFT ROD ASSEMBLY ............................................ 6-38

1 2 3 4 5 6 7 8 9

LOWR PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS).............................................................. 6-39 REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY............................................................................................ 6-39 DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY.......................................................................... 6-41 DISASSEMBLING/ASSEMBLING THE FRONT PROPELLER SHAFT ASSEMBLY............................................................................................ 6-43 REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY............ 6-44 REMOVING THE FORWARD GEAR ASSEMBLY.................................. 6-44 DISASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY . 6-45 DISASSEMBLING THE FORWARD GEAR ASSEMBLY ....................... 6-45 INSPECTING THE FORWARD GEAR .................................................... 6-46 INSPECTING THE BEARING.................................................................. 6-46 INSPECTING THE PROPELLER SHAFT HOUSING .............................. 6-46 INSPECTING THE DOG CLUTCH .......................................................... 6-46 INSPECTING THE PROPELLER SHAFTS .............................................. 6-46 ASSEMBLING THE FORWARD GEAR .................................................. 6-47 ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY ....... 6-47 INSTALLING THE FORWARD GEAR ASSEMBLY................................ 6-48 INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY.......... 6-49 DRIVE SHAFT (COUNTER ROTATION MODELS) ...................................... 6-50 REMOVING/INSTALLING THE DRIVE SHAFT...................................... 6-50 REMOVING THE DRIVE SHAFT ............................................................ 6-52 DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY ........... 6-52 DISASSEMBLING THE REVERSE GEAR .............................................. 6-52 INSPECTING THE PINION ..................................................................... 6-52 INSPECTING THE DRIVE SHAFT .......................................................... 6-52 INSPECTING THE DRIVE SHAFT HOUSING ........................................ 6-53 INSPECTING THE BEARINGS ............................................................... 6-53 ASSEMBLING THE REVERSE GEAR ASSEMBLY................................ 6-53 ASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY ................. 6-53 INSTALLING THE DRIVE SHAFT........................................................... 6-54 LOWER CASE ASSEMBLY (COUNTER ROTATION MODELS) ................. 6-55 DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY............................................................................................ 6-55 DISASSEMBLING THE LOWER CASE ASSEMBLY ............................. 6-56 INSPECTING THE DRIVE SHAFT SLEEVE ............................................ 6-56 INSPECTING THE NEEDLE BEARING................................................... 6-56 ASSEMBLING THE LOWER CASE ASSEMBLY ................................... 6-57

LOWR SHIMMING (REGULAR ROTATION MODELS)........................................... 6-58 SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA) .......................................................................... 6-59 SELECTING THE PINION SHIMS .......................................................... 6-59 SELECTING THE FORWARD GEAR SHIMS ......................................... 6-61 SELECTING THE REVERSE GEAR SHIMS............................................ 6-63 SHIMMING (REGULAR ROTATION MODELS) (EXCEPT FOR USA AND CANADA) ........................................................... 6-65 SELECTING THE PINION SHIMS .......................................................... 6-65 SELECTING THE FORWARD GEAR SHIMS ......................................... 6-67 SELECTING THE REVERSE GEAR SHIM .............................................. 6-68 BACKLASH (REGULAR ROTATION MODELS)........................................... 6-70 MEASURING THE FORWARD GEAR BACKLASH ............................... 6-70 MEASURING THE REVERSE GEAR BACKLASH.................................. 6-71 SHIMMING (COUNTER ROTATION MODELS) .......................................... 6-74 SHIMMING (COUNTER ROTATION MODELS) (FOR USA AND CANADA) .......................................................................... 6-75 SELECTING THE PINION SHIMS .......................................................... 6-75 SELECTING THE REVERSE GEAR SHIMS............................................ 6-77 SELECTING THE FORWARD GEAR SHIMS ......................................... 6-78 SELECTING THE PROPELLER SHAFT SHIMS...................................... 6-80 SHIMMING (COUNTER ROTATION MODELS) (EXCEPT FOR USA AND CANADA) ........................................................... 6-81 SELECTING THE PINION SHIMS .......................................................... 6-81 SELECTING THE REVERSE GEAR SHIMS............................................ 6-83 SELECTING THE FORWARD GEAR SHIMS ......................................... 6-84 SELECTING THE PROPELLER SHAFT SHIMS...................................... 6-86 BACKLASH (COUNTER ROTATION MODELS) .......................................... 6-87 MEASURING THE FORWARD GEAR BACKLASH ............................... 6-87 MEASURING THE REVERSE GEAR BACKLASH.................................. 6-88

LOWR

LOWER UNIT (REGULAR ROTATION MODELS)

REMOVING/INSTALLING THE LOWER UNIT (EXCEPT FOR B115)

6010

Order 1 2 3 4 5 6 7

Job/Part Speedometer hose Cotter pin Propeller nut Washer Washer Propeller Spacer

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 1

Remarks

Continued on next page.

6-1

LOWR

LOWER UNIT (REGULAR ROTATION MODELS)

6010

Order 8 9 10 11 12 13

Job/Part Bolt Trim tab Bolt Bolt Lower unit Dowel pin

Qâ&#x20AC;&#x2122;ty 1 1 1 6 1 2

Remarks

(with washer) (with washer)

For installation, reverse the removal procedure.

6-2

LOWR

LOWER UNIT (REGULAR ROTATION MODELS)

6 REMOVING/INSTALLING THE LOWER UNIT (FOR B115)

6315

Order 1 2 3 4 5 6 7 8 9 10 11

Job/Part Speedometer hose Cotter pin Propeller nut Washer Washer Propeller Spacer Bolt Bolt Lower unit Dowel pin

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 1 1 6 1 2

Remarks

(with washer) (with washer)

For installation, reverse the removal procedure. 6-3

LOWR

LOWER UNIT (REGULAR ROTATION MODELS)

REMOVING THE PROPELLER Remove: • Propeller

WARNING Do not hold the propeller with your hands when removing or installing it. Be sure to remove the battery leads from the batteries and the engine stop lanyard from the engine stop laynard switch. Put a block of wood between the cavitation plate and propeller to keep the propeller from turning.

6016

INSPECTING THE PROPELLER Inspect: • Blades • Splines Cracks/damage/wear → Replace.

INSTALLING THE PROPELLER Install: • Propeller

WARNING Do not hold the propeller with your hands when removing or installing it. Be sure to remove the battery leads from the batteries and the engine stop lanyard from the engine stop lanyard switch. Put a block of wood between the cavitation plate and propeller to keep the propeller from turning.

6017

NOTE: If the groove in the propeller nut is not aligned with the cotter pin hole, tighten the nut further until they are aligned.

6-4

LOWR

WATER PUMP (REGULAR ROTATION MODELS)

REMOVING/INSTALLING THE WATER PUMP (EXCEPT FOR B115)

6020

Order

Job/Part

Q’ty

Lower unit 1 2 3 4 5 6 7

Bolt Plate washer Impeller housing Impeller housing cup Grommet Spacer Collar

Remarks Refer to “LOWER UNIT (REGULAR ROTATION MODELS)” on page 6-1.

4 4 1 1 1 1 1 Continued on next page.

6-5

LOWR

WATER PUMP (REGULAR ROTATION MODELS)

6020

Order 8 9 10 11 12 13 14 15

Job/Part Spacer Washer Wave washer Impeller Woodruff key Impeller plate Gasket Dowel pin

Qâ&#x20AC;&#x2122;ty 1 2 1 1 1 1 1 2

Remarks

Not reusable For installation, reverse the removal procedure.

6-6

LOWR

WATER PUMP (REGULAR ROTATION MODELS)

6 REMOVING/INSTALLING THE WATER PUMP (FOR B115)

6330

Order

Job/Part

Q’ty

Lower unit 1 2 3 4 5 6 7

Bolt Plate washer Impeller housing Impeller housing cup Grommet Spacer Drive shaft collar

Remarks Refer to “LOWER UNIT (REGULAR ROTATION MODELS)” on page 6-1.

4 4 1 1 1 1 1 Continued on next page.

6-7

LOWR

WATER PUMP (REGULAR ROTATION MODELS)

6330

Order 8 9 10 11 12

Job/Part Spacer Washer Wave washer Impeller Woodruff key

Qâ&#x20AC;&#x2122;ty 1 2 1 1 1

Remarks

For installation, reverse the removal procedure.

6-8

LOWR

WATER PUMP (REGULAR ROTATION MODELS)

INSPECTING THE IMPELLER HOUSING Inspect: • Impeller housing Cracks/damage → Replace.

INSPECTING THE IMPELLER AND IMPELLER HOUSING CUP Inspect: • Impeller • Impeller housing cup Cracks/damage → Replace any defective parts.

INSPECTING THE WOODRUFF KEY Inspect: • Woodruff key Damage/wear → Replace.

INSTALLING THE IMPELLER AND IMPELLER HOUSING 1. Install: • Washers 1 • Wave washer 2 • Spacer 3 • Collar 4 NOTE: • The collar and spacer should fit together firmly. • Install the collar with some appropriate tool a that fits over the drive shaft as shown.

6025

2. Install: • O-ring 1 • Impeller housing cup 2 • Impeller housing 3 • O-ring 4 NOTE: • When installing the impeller housing cup, align its projection with the hole in the impeller housing. • When installing the water pump housing, turn the drive shaft clockwise. 6030

6-9

LOWR

SHIFT ROD ASSEMBLY (REGULAR ROTATION MODELS)

REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY (EXCEPT FOR B115)

6035

Order

1 2 3 4 5 6

Job/Part Impeller plate Bolt Shift rod assembly Shift rod Spring Oil seal housing Oil seal

Q’ty

3 1 1 1 1 1

Remarks Refer to “WATER PUMP (REGULAR ROTATION MODELS)” on page 6-5. (with washer)

For installation, reverse the removal procedure.

6-10

LOWR

SHIFT ROD ASSEMBLY (REGULAR ROTATION MODELS)

6 REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY (FOR B115)

6335

Order

1 2 3 4 5 6 7 8

Job/Part Woodruff key Bolt Plate washer Oil seal housing cover Impeller plate Gasket Oil seal housing O-ring Shift rod

Q’ty

3 3 1 1 1 1 1 1

Remarks Refer to “WATER PUMP (REGULAR ROTATION MODELS)” on page 6-5. (with washer)

Not reusable Not reusable

For installation, reverse the removal procedure.

6-11

LOWR

SHIFT ROD ASSEMBLY (REGULAR ROTATION MODELS)

REMOVING THE SHIFT ROD ASSEMBLY (EXCEPT FOR B115) Remove: • Shift rod assembly NOTE: Remove the shift rod assembly when the shift rod is in the neutral position.

REMOVING THE SHIFT ROD ASSEMBLY (FOR B115) a

1. Remove: • Oil seal housing Removing steps (1) Insert a flat-head screwdriver under each projection a. (2) Alternating between each side of the oil seal housing 1, slowly lift the oil seal housing until it is fully removed from the lower unit.

1 6336

2. Remove: • Shift rod NOTE: Remove the shift rod when it is in the neutral position.

6-12

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)

REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY

6040

Order

Job/Part

Q’ty

Gear oil Shift rod assembly

1 2 3 4

Ring nut Claw washer Propeller shaft housing assembly Straight key

1 1 1 1

6-13

Remarks Refer to “CHANGING AND INSPECTING THE GEAR OIL” on page 3-19. Refer to “SHIFT ROD ASSEMBLY (REGULAR ROTATION MODELS)” on page 6-10.

(except for B115) Continued on next page.

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)

6040

Order 5 6 7 8 9

Job/Part Straight key Reverse gear shim Propeller shaft assembly Washer Propeller shaft housing

Qâ&#x20AC;&#x2122;ty 1 * 1 1 1

Remarks (for B115)

For installation, reverse the removal procedure. *: As required

6-14

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)

6 DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING

6045

Order 1 2 3 4 5 6 7

Job/Part O-ring Reverse gear Thrust washer Ball bearing Oil seal Needle bearing Propeller shaft housing

Qâ&#x20AC;&#x2122;ty 1 1 1 1 2 1 1

Remarks

For assembly, reverse the disassembly procedure.

6-15

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)

6 DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASSEMBLY

6100

Order 1 2 3 4 5 6 7 8 9

Job/Part Spring Pin Dog clutch Shift rod joint Shift rod joint slider Ball Spring Ball Propeller shaft

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 4 1 2 1

Remarks

For assembly, reverse the disassembly procedure.

6-16

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)

REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY 1. Straighten: • Claw washer tabs 2. Remove: • Ring nut • Claw washer Ring nut wrench ....................... 1 YB-34447 / 90890-06511 Ring nut wrench extension ..... 2 90890-06513

6050

3. Remove: • Propeller shaft housing assembly 1

Propeller shaft housing puller . YB-06207 / 90890-06502 Universal puller......................... YB-06117 Guide plate................................ 90890-06501 Center bolt ................................ 90890-06504

2 6054

1 2 3 4

Å For USA and Canada ı Except for USA and Canada

6055

DISASSEMBLING THE PROPELLER SHAFT HOUSING

1. Remove: • Reverse gear Slide hammer............................ YB-06096 Bearing separator ..................... 90890-06534 Guide plate................................ 90890-06501 Guide plate stand ..................... 90890-06538 Bearing puller............................ 90890-06535 Small universal claws .............. 90890-06536

6060

Å For USA and Canada ı Except for USA and Canada 6065

6-17

1 2 3 4 5 6

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)

2. Remove: • Ball bearing

Slide hammer............................ YB-06096 Guide plate................................ 90890-06501 Guide plate stand ..................... 90890-06538 Bearing puller............................ 90890-06535 Small universal claws .............. 90890-06536

6070

1 2 3 4 5

Å For USA and Canada ı Except for USA and Canada

6075

3. Remove: • Oil seal • Needle bearing Bearing/oil seal attachment .... 1 YB-06196 / 90890-06653 Driver rod .................................. 2 YB-06071 / 90890-06652 6080

INSPECTING THE REVERSE GEAR Inspect: • Teeth • Dogs Wear/damage → Replace the reverse gear.

INSPECTING THE BEARING Inspect: • Bearing Pitting/rumbling → Replace.

INSPECTING THE PROPELLER SHAFT HOUSING Inspect: • Propeller shaft housing Cracks/damage → Replace.

6-18

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)

INSPECTING THE DOG CLUTCH Inspect: • Dog clutch Damage/wear → Replace.

INSPECTING THE PROPELLER SHAFT Inspect: • Propeller shaft Damage/wear → Replace.

ASSEMBLING THE PROPELLER SHAFT HOUSING 1. Install: • Needle bearing Needle bearing installation position a 24.75 - 25.25 mm (0.974 - 0.994 in) 6085

Bearing/oil seal attachment .... 1 YB-06196 / 90890-06653 Driver rod .................................. 2 YB-06071 / 90890-06604 Bearing/oil seal depth plate .... 3 90890-06603 Å For USA and Canada ı Except for USA and Canada 6086

2. Install: • Oil seal Oil seal installation position a 4.75 - 5.25 mm (0.187 - 0.207 in) Bearing/oil seal attachment YB-06195 / 90890-06633 6090

ASSEMBLING THE REVERSE GEAR Install: • Ball bearing Bearing/oil seal attachment YB-06200 / 90890-06661

6092

6-19

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)

INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY Install: • Propeller shaft housing assembly • Claw washer • Ring nut Ring nut wrench ....................... 1 YB-34447 / 90890-06511 Ring nut wrench extension ..... 2 90890-06513

6095

NOTE: To secure the ring nut, bend one tab into the slot in the ring nut and the other tabs toward the propeller shaft housing assembly.

6-20

LOWR

DRIVE SHAFT (REGULAR ROTATION MODELS)

REMOVING/INSTALLING THE DRIVE SHAFT

6105

Order

1 2 3 4 5 6 7

Job/Part Propeller shaft housing assembly

Nut Pinion Bolt Drive shaft housing assembly Pinion shim Thrust bearing Drive shaft

Q’ty

1 1 4 1 * 1 1

Remarks Refer to “PROPELLER SHAFT HOUSING ASSEMBLY (REGULAR ROTATION MODELS)” on page 6-13.

(with washer)

Continued on next page. *: As required

6-21

LOWR

DRIVE SHAFT (REGULAR ROTATION MODELS)

6105

Order 8 9 10 11 12 13 14 15 16

Job/Part Forward gear assembly O-ring Oil seal cover Oil seal Needle bearing Drive shaft housing Tapered roller bearing Needle bearing Forward gear

Qâ&#x20AC;&#x2122;ty 1 1 1 2 1 1 1 1 1

Remarks

Not reusable

For installation, reverse the removal procedure.

6-22

LOWR

DRIVE SHAFT (REGULAR ROTATION MODELS)

REMOVING THE DRIVE SHAFT Loosen: • Pinion nut Drive shaft holder ..................... 1 YB-06201 / 90890-06520 Pinion nut holder ...................... 2 90890-06505 Pinion nut holder attachment . 3 90890-06507

6110

DISASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY Remove: • Needle bearing Bearing/oil seal attachment .... 1 YB-06196 / 90890-06610 Driver rod .................................. 2 YB-06071 / 90890-06652 6120

DISASSEMBLING THE FORWARD GEAR ASSEMBLY 1. Remove: • Tapered roller bearing Bearing separator YB-06219 / 90890-06534 6140

CAUTION: Do not reuse the bearing, always replace it with a new one. 2. Remove: • Needle bearing Slide hammer............................ YB-06096 Guide plate................................ 90890-06501 Guide plate stand ..................... 90890-06538 Bearing puller............................ 90890-06535 Small universal claws .............. 90890-06536

6145

6-23

1 2 3 4 5

LOWR

DRIVE SHAFT (REGULAR ROTATION MODELS)

INSPECTING THE PINION Inspect: • Teeth Damage/wear → Replace.

INSPECTING THE DRIVE SHAFT Inspect: • Drive shaft Damage/wear → Replace.

INSPECTING THE DRIVE SHAFT HOUSING Inspect: • Drive shaft housing Cracks/damage → Replace.

INSPECTING THE BEARINGS Inspect: • Bearings Pitting/rumbling → Replace.

ASSEMBLING THE FORWARD GEAR ASSEMBLY 1. Install: • Needle bearing Needle bearing installation position a 2.5 - 3.5 mm (0.098 - 0.138 in) 6150

Bearing/oil seal attachment .... 1 YB-06200 / 90890-06612 Driver rod .................................. 2 YB-06071 / 90890-06604 Bearing/oil seal depth plate .... 3 90890-06603

6-24

LOWR

DRIVE SHAFT (REGULAR ROTATION MODELS)

2. Install: • Tapered roller bearing Bearing/oil seal attachment 90890-06661

6155

ASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY

1. Install: • Needle bearing Position a 5.75 - 6.25 mm (0.226 - 0.246 in) Bearing/oil seal attachment .... 1 YB-06196 / 90890-06610 Driver rod .................................. 2 YB-06071 / 90890-06604 Bearing/oil seal depth plate .... 3 90890-06603

6125

Å For USA and Canada ı Except for USA and Canada

6126

2. Install: • Oil seal Oil seal installation position a 0.25 - 0.75 mm (0.010 - 0.030 in) Bearing/oil seal attachment .... 1 YB-06195 / 90890-06633 Driver rod .................................. 2 YB-06071 / 90890-06652

6130

6-25

LOWR

DRIVE SHAFT (REGULAR ROTATION MODELS)

INSTALLING THE DRIVE SHAFT Tighten: • Pinion nut Drive shaft holder ..................... 1 YB-06201 / 90890-06520 Pinion nut holder ...................... 2 90890-06505 Pinion nut holder attachment . 3 90890-06507

6111

6-26

Pinion nut 95 Nm (9.5 m • kgf, 68 ft • lb)

LOWR

LOWER CASE ASSEMBLY (REGULAR ROTATION MODELS)

DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY (EXCEPT FOR B115)

6160

Order

1 2 3 4 5 6

Job/Part Forward gear Drive shaft sleeve Needle bearing Tapered roller bearing outer race Forward gear shim Water seal Plate

Q’ty

Remarks Refer to “DRIVE SHAFT (REGULAR ROTATION MODELS)” on page 6-21.

1 1 1 * 1 1 For assembly, reverse the disassembly procedure.

*: As required

6-27

LOWR

LOWER CASE ASSEMBLY (REGULAR ROTATION MODELS)

6 DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY (FOR B115)

6465

Order

1 2 3 4

Job/Part Forward gear assembly Drive shaft sleeve Needle bearing Tapered roller bearing outer race Front gear shim

Q’ty

Remarks Refer to “DRIVE SHAFT (REGULAR ROTATION MODELS)” on page 6-21.

1 1 1 * For assembly, reverse the disassembly procedure.

*: As required

6-28

LOWR

LOWER CASE ASSEMBLY (REGULAR ROTATION MODELS)

DISASSEMBLING THE LOWER CASE ASSEMBLY 1. Remove: • Needle bearing Bearing/oil seal attachment .... 1 YB-06194 / 90890-06636 Driver rod .................................. 2 YB-06071 / 90890-06605 6165

2. Remove: • Tapered roller bearing outer race Slide hammer............................ 1 YB-06096 Bearing puller............................ 2 90890-06523 Large universal claws............... 3 90890-06532 6170

INSPECTING THE DRIVE SHAFT SLEEVE Inspect: • Drive shaft sleeve Damage/wear → Replace.

INSPECTING THE NEEDLE BEARING Inspect: • Needle bearing Pitting/rumbling → Replace.

ASSEMBLING THE LOWER CASE ASSEMBLY 1. Install: • Tapered roller bearing outer race Bearing/oil seal attachment .... 1 YB-06199 / 90890-06620 Driver rod .................................. 2 YB-06071 / 90890-06605 6175

6-29

LOWR

LOWER CASE ASSEMBLY (REGULAR ROTATION MODELS)

2. Install: • Needle bearing

Needle bearing installation position a 10.0 mm (0.39 in) (for B115) Needle bearing installation position b 184.0 mm (7.24 in) (except for B115) 139.0 mm (5.47 in) (for B115)

6485

Bearing/oil seal attachment .... 1 YB-06194 / 90890-06609 Driver rod .................................. 2 YB-06071 / 90890-06602 Bearing/oil seal depth plate .... 3 YB-06213 / 90890-06603 YB-34474 Å For USA and Canada ı Except for USA and Canada

6490

6-30

LOWR

LOWER UNIT (COUNTER ROTATION MODELS)

REMOVING/INSTALLING THE LOWER UNIT

6011

Order 1 2 3 4 5 6 7

Job/Part Cotter pin Propeller nut Washer Washer Propeller Spacer Bolt

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 1

Remarks

Continued on next page.

6-31

LOWR

LOWER UNIT (COUNTER ROTATION MODELS)

6011

Order 8 9 10 11 12

Job/Part Trim tab Bolt Bolt Lower unit Dowel pin

Qâ&#x20AC;&#x2122;ty 1 1 6 1 2

Remarks (with washer) (with washer)

For installation, reverse the removal procedure.

6-32

LOWR

LOWER UNIT (COUNTER ROTATION MODELS)

REMOVING THE PROPELLER Remove: • Propeller

WARNING Do not hold the propeller with your hands when removing or installing it. Be sure to remove the battery leads from the batteries and the engine stop lanyard from the engine stop lanyard switch. Put a block of wood between the cavitation plate and propeller to keep the propeller from turning.

6018

INSPECTING THE PROPELLER Inspect: • Blades • Splines Cracks/damage/wear → Replace.

INSTALLING THE PROPELLER Install: • Propeller

WARNING Do not hold the propeller with your hands when removing or installing it. Be sure to remove the battery leads from the batteries and the engine stop lanyard from the engine stop lanyard switch. Put a block of wood between the cavitation plate and propeller to keep the propeller from turning.

6019

NOTE: If the groove in the propeller nut is not aligned with the cotter pin hole, tighten the nut further until they are aligned.

6-33

LOWR

WATER PUMP (COUNTER ROTATION MODELS)

REMOVING/INSTALLING THE WATER PUMP

6020

Order

Job/Part

Q’ty

Lower unit 1 2 3 4 5 6 7

Bolt Plate washer Impeller housing Impeller housing cup Grommet Spacer Collar

Remarks Refer to “LOWER UNIT (COUNTER ROTATION MODELS)” on page 6-31.

4 4 1 1 1 1 1 Continued on next page.

6-34

LOWR

WATER PUMP (COUNTER ROTATION MODELS)

6020

Order 8 9 10 11 12 13 14 15

Job/Part Spacer Washer Wave washer Impeller Woodruff key Impeller plate Gasket Dowel pin

Qâ&#x20AC;&#x2122;ty 1 2 1 1 1 1 1 2

Remarks

Not reusable For installation, reverse the removal procedure.

6-35

LOWR

WATER PUMP (COUNTER ROTATION MODELS)

INSPECTING THE IMPELLER HOUSING Inspect: • Impeller housing Cracks/damage → Replace.

INSPECTING THE IMPELLER AND IMPELLER HOUSING CUP Inspect: • Impeller • Impeller housing cup Cracks/damage → Replace any defective parts.

INSPECTING THE WOODRUFF KEY Inspect: • Woodruff key Damage/wear → Replace.

6025

6-36

LOWR

SHIFT ROD ASSEMBLY (COUNTER ROTATION MODELS)

REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY

6195

Order

1 2 3 4 5 6

Job/Part Impeller plate Bolt Shift rod assembly Shift rod Spring Oil seal housing Oil seal

Q’ty

3 1 1 1 1 1

Remarks Refer to “WATER PUMP (COUNTER ROTATION MODELS)” on page 6-34. (with washer)

For installation, reverse the removal procedure.

6-37

LOWR

SHIFT ROD ASSEMBLY (COUNTER ROTATION MODELS)

REMOVING THE SHIFT ROD ASSEMBLY Remove: â&#x20AC;¢ Shift rod assembly NOTE: Remove the shift rod assembly when the shift rod is in the neutral position.

6-38

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY

6200

Order

Job/Part

Q’ty

Gear oil Shift rod assembly

1 2 3

Ring nut Claw washer Propeller shaft housing assembly

Remarks Refer to “CHANGING AND INSPECTING THE GEAR OIL” on page 3-19. Refer to “SHIFT ROD ASSEMBLY (COUNTER ROTATION MODELS)” on page 6-37.

1 1 1 Continued on next page.

6-39

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

6200

Order 4 5 6 7

Job/Part Straight key Front propeller shaft assembly Thrust washer Forward gear shim

Qâ&#x20AC;&#x2122;ty 1 1 1 *

Remarks

For installation, reverse the removal procedure. *: As required

6-40

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

6 DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY

6205

Order 1 2 3 4 5 6 7

Job/Part O-ring Forward gear assembly Rear propeller shaft Thrust bearing Propeller shaft shim Needle bearing Oil seal

Qâ&#x20AC;&#x2122;ty 1 1 1 1 * 1 2

Remarks

Continued on next page. *: As required

6-41

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

6205

Order 8 9 10 11 12 13 14

Job/Part Needle bearing Propeller shaft housing Forward gear Thrust washer Tapered roller bearing outer race Tapered roller bearing Needle bearing

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 1

Remarks

Not reusable For assembly, reverse the disassembly procedure.

6-42

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

6 DISASSEMBLING/ASSEMBLING THE FRONT PROPELLER SHAFT ASSEMBLY

6235

Order 1 2 3 4 5 6 7 8 9

Job/Part Spring Pin Dog clutch Shift rod joint Shift rod joint slider Ball Spring Ball Front propeller shaft

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 4 1 2 1

Remarks

For assembly, reverse the disassembly procedure.

6-43

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

6050

3. Remove: • Propeller shaft housing assembly Slide hammer attachment....... 1 YB-06335 / 90890-06514 Slide hammer............................ 2 YB-06096 / 90890-06531

6215

REMOVING THE FORWARD GEAR ASSEMBLY Remove: • Rear propeller shaft • Forward gear assembly Propeller shaft housing puller . 1 YB-06207 / 90890-06502 Universal puller YB-06117 Guide plate................................ 2 90890-06501 Center bolt ................................ 3 90890-06504

6220

6-44

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

DISASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY

1. Remove: • Needle bearing Slide hammer............................ YB-06096 Guide plate................................ 90890-06501 Guide plate stand ..................... 90890-06538 Bearing puller............................ 90890-06535 Small universal claws .............. 90890-06536

6221

1 2 3 4 5

Å For USA and Canada ı Except for USA and Canada

6222

2. Remove: • Oil seal • Needle bearing Bearing/oil seal attachment .... 1 YB-06196 / 90890-06653 Driver rod .................................. 2 YB-06071 / 90890-06652 6225

DISASSEMBLING THE FORWARD GEAR ASSEMBLY 1. Remove: • Tapered roller bearing Bearing separator YB-06219 / 90890-06534 6230

CAUTION: Do not reuse the bearing, always replace it with a new one.

6-45

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

2. Remove: • Needle bearing

6223

1 2 3 4 5

Å For USA and Canada ı Except for USA and Canada

6224

INSPECTING THE FORWARD GEAR Inspect: • Teeth • Dogs Damage/wear → Replace.

INSPECTING THE BEARING Inspect: • Bearing Pitting/rumbling → Replace.

INSPECTING THE PROPELLER SHAFT HOUSING Inspect: • Propeller shaft housing Cracks/damage → Replace.

INSPECTING THE DOG CLUTCH Inspect: • Dog clutch Damage/wear → Replace.

INSPECTING THE PROPELLER SHAFTS Inspect: • Propeller shafts Damage/wear → Replace.

6-46

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

ASSEMBLING THE FORWARD GEAR

Install: • Needle bearing Needle bearing installation position a 10.25 - 10.75 mm (0.40 - 0.42 in) Bearing/oil seal attachment .... 1 YB-06378 / 90890-06610 Driver rod .................................. 2 YB-06071 / 90890-06604 Bearing/oil seal depth plate .... 3 90890-06603

6226

Å For USA and Canada ı Except for USA and Canada

6227

ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY

1. Install: • Needle bearing Needle bearing installation position a 34.25 - 34.75 mm (1.348 - 1.368 in) 6228

Bearing/oil seal attachment .... 1 YB-06337 / 90890-06608 Driver rod .................................. 2 YB-06071 / 90890-06604 Bearing/oil seal depth plate .... 3 90890-06603

Å For USA and Canada ı Except for USA and Canada 6229

6-47

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

2. Install: • Needle bearing

Needle bearing installation position a 24.75 - 25.25 mm (0.974 - 0.994 in) Bearing/oil seal attachment .... 1 YB-06196 / 90890-06610 Driver rod .................................. 2 YB-06071 / 90890-06604 Bearing/oil seal depth plate .... 3 90890-06603

6231

Å For USA and Canada ı Except for USA and Canada

6086

3. Install: • Oil seal Oil seal installation position a 4.75 - 5.25 mm (0.187 - 0.207 in) Bearing/oil seal attachment YB-06195 / 90890-06633 6232

INSTALLING THE FORWARD GEAR ASSEMBLY 1. Install: • Rear propeller shaft • Tapered roller bearing Bearing/oil seal attachment .... 1 YB-06430 / 90890-06656 Driver rod .................................. 2 YB-06071 / 90890-06606

6241

2. Install: • Thrust washer • Forward gear

6233

6-48

LOWR

PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)

6095

NOTE: To secure the ring nut, bend one tab into the slot in the ring nut and the other tabs toward the propeller shaft housing assembly.

6-49

LOWR

DRIVE SHAFT (COUNTER ROTATION MODELS)

REMOVING/INSTALLING THE DRIVE SHAFT

6240

Order

1 2 3 4 5 6 7

Job/Part Propeller shaft housing assembly

Nut Pinion Bolt Drive shaft housing assembly Pinion shim Thrust bearing Drive shaft

Q’ty

1 1 4 1 * 1 1

Remarks Refer to “PROPELLER SHAFT HOUSING ASSEMBLY (COUNTER ROTATION MODELS)” on page 6-39.

(with washer)

Continued on next page. *: As required

6-50

LOWR

DRIVE SHAFT (COUNTER ROTATION MODELS)

6240

Order 8 9 10 11 12 13 14 15 16

Job/Part Reverse gear assembly Thrust bearing O-ring Oil seal cover Oil seal Needle bearing Drive shaft housing Needle bearing Reverse gear

Qâ&#x20AC;&#x2122;ty 1 1 1 1 2 1 1 1 1

Remarks

For installation, reverse the removal procedure.

6-51

LOWR

DRIVE SHAFT (COUNTER ROTATION MODELS)

6110

DISASSEMBLING THE REVERSE GEAR Remove: • Needle bearing Slide hammer............................ YB-06096 Guide plate................................ 90890-06501 Guide plate stand ..................... 90890-06538 Bearing puller............................ 90890-06535 Small universal claws .............. 90890-06536

6275

INSPECTING THE PINION Inspect: • Teeth Damage/wear → Replace.

INSPECTING THE DRIVE SHAFT Inspect: • Drive shaft Damage/wear → Replace. 6-52

1 2 3 4 5

LOWR

DRIVE SHAFT (COUNTER ROTATION MODELS)

INSPECTING THE DRIVE SHAFT HOUSING Inspect: • Drive shaft housing Cracks/damage → Replace.

INSPECTING THE BEARINGS Inspect: • Bearings Pitting/rumbling → Replace.

ASSEMBLING THE REVERSE GEAR ASSEMBLY Install: • Needle bearing Needle bearing installation position a 2.5 - 3.5 mm (0.098 - 0.138 in)

6270

Bearing/oil seal attachment .... 1 YB-06200 / 90890-06612 Driver rod .................................. 2 YB-06071 / 90890-06604 Bearing/oil seal depth plate .... 3 90890-06603

ASSEMBLING THE DRIVE SHAFT HOUSING ASSEMBLY

6125

Å For USA and Canada ı Except for USA and Canada

6126

6-53

LOWR

DRIVE SHAFT (COUNTER ROTATION MODELS)

6130

6111

6-54

Pinion nut 95 Nm (9.5 m • kgf, 68 ft • lb)

LOWR

LOWER CASE ASSEMBLY (COUNTER ROTATION MODELS)

DISASSEMBLING/ASSEMBLING THE LOWER CASE ASSEMBLY

6290

Order

1 2 3 4 5 6 7

Job/Part Reverse gear Drive shaft sleeve Needle bearing Bearing retainer Reverse gear shim Needle bearing Water seal Plate

Q’ty

Remarks Refer to “DRIVE SHAFT (COUNTER ROTATION MODELS)” on page 6-50.

1 1 1 * 1 1 1 For assembly, reverse the disassembly procedure.

*: As required

6-55

LOWR

LOWER CASE ASSEMBLY (COUNTER ROTATION MODELS)

2. Remove: • Roller bearing Slide hammer............................ 1 YB-06096 Bearing puller............................ 2 90890-06523 Large universal claws............... 3 90890-06532 6300

3. Remove: • Needle bearing Bearing/oil seal attachment .... 1 YB-06376 / 90890-06607 Driver rod .................................. 2 YB-06071 / 90890-06652

6413

INSPECTING THE DRIVE SHAFT SLEEVE Inspect: • Drive shaft sleeve Damage/wear → Replace.

INSPECTING THE NEEDLE BEARING Inspect: • Needle bearing Pitting/rumbling → Replace.

6-56

LOWR

LOWER CASE ASSEMBLY (COUNTER ROTATION MODELS)

ASSEMBLING THE LOWER CASE ASSEMBLY 1. Install: • Needle bearing Needle bearing installation position a 0.75 - 1.25 mm (0.030 - 0.049 in) 6416

Bearing/oil seal attachment .... 1 YB-06376 / 90890-06607 Driver rod .................................. 2 YB-06071 / 90890-06652

2. Install: • Bearing retainer Bearing/oil seal attachment .... 1 YB-06377 / 90890-06630 Driver rod .................................. 2 YB-06071 / 90890-06605

6305

3. Install: • Needle bearing

6314

Needle bearing installation position a 184.0 mm (7.24 in) Bearing/oil seal attachment .... 1 YB-06194 / 90890-06609 Driver rod .................................. 2 YB-06071 / 90890-06602 Bearing/oil seal depth plate .... 3 YB-06213 / 90890-06603

6-57

LOWR

SHIMMING (REGULAR ROTATION MODELS)

NOTE: • There is no need to select shims when reassembling with the original case and inner parts. • Shim calculations are required when reassembling with the original inner parts and a new case (the difference between the original inner parts and the new case). • Measurements and adjustments are required when replacing the inner part(s). Å Except for B115 ı For B115

6495

6-58

SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA)

LOWR

SELECTING THE PINION SHIMS NOTE: Find the shim thickness (T3) by selecting shims until the specified value (M0) is obtained with the special tool.

6505

1. Measure: • Specified measurement (M) Out of specified value (M0) → Adjust.

Specified value (M0) = 1.00 + P/100 mm Å Except for B115 ı For B115 6520

Measuring steps (1) Calculate the specified value (M0).

NOTE: • “P” is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units. If the “P” mark is missing or unreadable, assume a “P” value of “0”, and check the backlash when the unit is assembled. • If the “P” mark is negative (–), then subtract the “P” value from the measurement.

6510

Example: If “P” is “+5”, then M0 = 1.00 + (+5)/100 mm = 1.00 + 0.05 mm = 1.05 mm If “P” is “–3”, then M0 = 1.00 + (–3)/100 mm = 1.00 – 0.03 mm = 0.97 mm

6740

6-59

SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA)

LOWR

(2) Install the pinion height gauge, drive shaft, thrust bearing 1, and shim(s) 2.

Pinion height gauge YB-34432-6, -11, -97 Å Except for B115 ı For B115

NOTE: If the original shim(s) is unavailable, start with a 0.50-mm shim.

6515

(3) Install the pinion and pinion nut.

Pinion nut 95 Nm (9.5 m • kgf, 69 ft • lb)

6745

(4) Measure the specified measurement (M).

NOTE: • Measure the clearance between the pinion height gauge and the lower surface of the pinion as shown. • Perform the same measurement at three points on the pinion. • Find the average of the measurements (M).

6520

2. Adjust: • Shim thickness (T3) Remove or add shim(s). Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: (M0) – (M) should be as close to “0” as possible.

6-60

LOWR

SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA)

SELECTING THE FORWARD GEAR SHIMS NOTE: Find the shim thickness (T1) by selecting shims until the specified value (M0) is obtained with the special tool. 6525

1. Measure: • Specified measurement (M) Out of specified value (M0) → Adjust. Specified value (M0) = 1.80 + F/100 mm Å Except for B115 ı For B115 6526

Measuring steps (1) Calculate the specified value (M0).

NOTE: • “F” is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units. If the “F” mark is missing or unreadable, assume an “F” value of “0”, and check the backlash when the unit is assembled. • If the “F” mark is negative (–), then subtract the “F” value from the measurement.

6530

Example: If “F” is “+5”, then M0 = 1.80 + (+5)/100 mm = 1.80 + 0.05 mm = 1.85 mm If “F” is “–3”, then M0 = 1.80 + (–3)/100 mm = 1.80 – 0.03 mm = 1.77 mm

6760

6-61

LOWR

SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA)

(2) Install the shimming gauge, bearing 1, and shim(s) 2. Shimming gauge YB-34446-1, -3, -5, -7 NOTE: If the original shim(s) is unavailable, start with a 0.50-mm shim. (3) Measure the specified measurement (M).

6535

2. Adjust: • Shim thickness (T1) Remove or add shim(s). Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: (M0) – (M) should be as close to “0” as possible.

6-62

LOWR

SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA)

SELECTING THE REVERSE GEAR SHIMS NOTE: Find the shim thickness (T2) by selecting shims until the specified value (M0) is obtained with the special tool. 6545

1. Measure: • Specified measurement (M) Out of specified value (M0) → Adjust.

Specified value (M0) = 1.80 – R/100 mm Å Except for B115 ı For B115 6555

Measuring steps (1) Calculate the specified value (M0).

NOTE: • “R” is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units. If the “R” mark is missing or unreadable, assume an “R” value of “0”, and check the backlash when the unit is assembled. • If the “R” mark is negative (–), then add the “R” value to the measurement.

6550

Example: If “R” is “+5”, then M0 = 1.80 – (+5)/100 mm = 1.80 – 0.05 mm = 1.75 mm If “R” is “–3”, then M0 = 1.80 – (–3)/100 mm = 1.80 + 0.03 mm = 1.83 mm

6775

6-63

LOWR

SHIMMING (REGULAR ROTATION MODELS) (FOR USA AND CANADA)

(2) Install the shimming gauge, bearing, thrust washer, reverse gear, and shim(s).

Shimming gauge YB-34468-2 NOTE: • If the original shim(s) is unavailable, start with a 0.50-mm shim. • Turn the reverse gear assembly a few times until the gear and bearing are horizontal.

6555

(3) Measure the specified measurement (M). 2. Adjust: • Shim thickness (T2) Remove or add shim(s). Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: (M0) – (M) should be as close to “0” as possible.

6-64

LOWR

SHIMMING (REGULAR ROTATION MODELS) (EXCEPT FOR USA AND CANADA)

SELECTING THE PINION SHIMS NOTE: Select the shim thickness (T3) by using the specified measurement(s) and the calculation formula. Select: • Shim thickness (T3)

6575

Selecting steps (1) Measure (M3). Digital caliper 90890-06704 NOTE: Install the bearing housing 1, thrust bearing 2, and washer 3.

6580

(2) Install the pinion and pinion nut.

Pinion nut 95 Nm (9.5 m • kgf, 69 ft • lb)

(3) Install the pinion height gauge. Pinion height gauge 90890-06702 NOTE: After the wing nuts contact the fixing plate, tighten them another 1/4 of a turn. (4) Measure (M4). Digital caliper 90890-06704 NOTE: • Measure the clearance between the pinion height gauge and the pinion, as shown. • Perform the same measurement at three points on the pinion. • Find the average of the measurements (M4).

6585

6-65

LOWR

SHIMMING (REGULAR ROTATION MODELS) (EXCEPT FOR USA AND CANADA)

(5) Calculate the pinion shim thickness (T3). Pinion shim thickness (T3) = 62.5 + P/100 – M3 – M4 NOTE: • “P” is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units. If the “P” mark is missing or unreadable, assume a “P” value of “0”, and check the backlash when the unit is assembled. • If the “P” mark is negative (–), then add the “P” value to the measurement.

6590

Example: If M3 is “46.85 mm”, M4 is “15.12 mm” and P is “–5”, then T3 = 62.5 + (–5)/100 – 46.85 – 15.12 mm = 62.5 – 0.05 – 46.85 – 15.12 mm = 0.48 mm (6) Select the pinion shim(s) (T3). Calculated numeral at 1/100th place

Rounded numeral

More than

or less

0.00

0.02

0.00

0.02

0.05

0.02

0.05

0.08

0.05

0.08

0.10

0.08

Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm

6-66

LOWR

SHIMMING (REGULAR ROTATION MODELS) (EXCEPT FOR USA AND CANADA)

SELECTING THE FORWARD GEAR SHIMS NOTE: Select the shim thickness (T1) by using the specified measurement(s) and the calculation formula. Select: • Shim thickness (T1)

6595

Selecting steps (1) Measure (M1). Shimming plate ........................ 1 90890-06701 Digital caliper ............................ 2 90890-06704 6600

NOTE: • Turn the roller bearing outer race two or three times so the rollers seat. Then, measure the height of the bearing, as shown. • Perform the same measurement at three points on the roller bearing outer race. • Find the average of the measurements (M1).

(2) Calculate the forward gear shim thickness (T1). Forward gear shim thickness (T1) (T1) = 24.6 + F/100 – M1 NOTE: • “F” is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units. If the “F” mark is missing or unreadable, assume an “F” value of “0”, and check the backlash when the unit is assembled. • If the “F” mark is negative (–), then subtract the “F” value from the measurement.

6610

6-67

LOWR

SHIMMING (REGULAR ROTATION MODELS) (EXCEPT FOR USA AND CANADA)

Example: If M1 is “24.10 mm” and F is “+5”, then T1 = 24.6 + (+5)/100 – 24.10 mm = 24.6 + 0.05 – 24.10 mm = 0.55 mm (3) Select the forward gear shim(s) (T1). Calculated numeral at 1/100th place

Rounded numeral

More than

or less

0.00

0.02

0.00

0.02

0.05

0.02

0.05

0.08

0.05

0.08

0.10

0.08

Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm

SELECTING THE REVERSE GEAR SHIM NOTE: Select the shim thickness (T2) by using the specified measurement(s) and the calculation formula. 6615

Select: • Shim thickness (T2) Selecting steps (1) Measure (M2). Shimming plate ........................ 1 90890-06701 Digital caliper ............................ 2 90890-06704

6620

NOTE: • Measure the height of the gear as shown. • Perform the same measurement at three points on the gear. • Find the average of the measurements (M2).

6-68

LOWR

SHIMMING (REGULAR ROTATION MODELS) (EXCEPT FOR USA AND CANADA)

(2) Calculate the reverse gear shim thickness (T2). Reverse gear shim thickness (T2) = M2 – 27.4 – R/100 NOTE: • “R” is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units. If the “R” mark is missing or unreadable, assume a “R” value of “0”, and check the backlash when the unit is assembled. • If the “R” mark is negative (–), then subtract the “R” value from the measurement. Example: If M2 is “27.95 mm”, R is “+2”, then T2 = 27.95 – 27.4 – (+2)/100 mm = 27.95 – 27.4 – 0.02 mm = 0.53 mm

6625

(3) Select the reverse gear shim(s) (T2). Calculated numeral at 1/100th place

Rounded numeral

More than

or less

0.00

0.02

0.05

0.08

0.10

Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm

6-69

LOWR

BACKLASH (REGULAR ROTATION MODELS)

BACKLASH (REGULAR ROTATION MODELS) 6 NOTE: • Do not install the water pump components when measuring the backlash. • Measure both the forward and reverse gear backlashes. • If both the forward and reverse gear backlashes are larger than specification, the pinion may be too high. • If both the forward and reverse gear backlashes are smaller than specification, the pinion may be too low.

MEASURING THE FORWARD GEAR BACKLASH 1. Measure: • Forward gear backlash Out of specification → Adjust. Forward gear backlash 0.32 - 0.50 mm (0.013 - 0.020 in) Measuring steps (1) Set the shift rod into the neutral position. Shift rod wrench YB-06052 / 90890-06052 (2) Install the propeller shaft housing puller so it pushes against the propeller shaft. 6645

6650

6-70

Center bolt 10 Nm (1.0 m • kgf, 7.2 ft • lb)

1 2 3 4

LOWR

BACKLASH (REGULAR ROTATION MODELS)

(3) Install the backlash indicator onto the drive shaft (on the 22.4 mm (0.88 in) diameter portion of the drive shaft). Backlash indicator .................... 5 YB-06265 / 90890-06706 (4) Install the dial gauge onto the lower unit and have the dial gauge plunger contact the mark on the backlash indicator.

6655

Magnetic-base plate................. 6 YB-07003 / 90890-07003 Dial gauge set ........................... 7 YU-03097 / 90890-01252 Magnetic base........................... 8 YU-34481 / 90890-06705 (5) Set the lower unit upside down. (6) Slowly turn the drive shaft clockwise and counterclockwise. When the drive shaft stops in each direction, measure the backlash. 2. Adjust: • Forward gear shim Remove or add shim(s). Forward gear backlash

Shim thickness

Less than To be decreased by 0.32 mm (0.013 in) (0.41 – M) × 0.63 More than To be increased by 0.50 mm (0.020 in) (M – 0.41) × 0.63 M: Measurement

MEASURING THE REVERSE GEAR BACKLASH 1. Measure: • Reverse gear backlash Out of specification → Adjust. Reverse gear backlash 0.80 - 1.17 mm (0.031 - 0.046 in)

6-71

LOWR

BACKLASH (REGULAR ROTATION MODELS)

Measuring steps (1) Set the shift rod into the neutral position. Shift rod wrench YB-06052 / 90890-06052

6645

(2) Load the reverse gear by installing the propeller without the spacer 1 and then tighten the propeller nut.

Propeller nut 10 Nm (1.0 m â&#x20AC;˘ kgf, 7.2 ft â&#x20AC;˘ lb)

6665

(3) Install the backlash indicator onto the drive shaft (on the 22.4 mm (0.88 in) diameter portion of the drive shaft). Backlash indicator .................... 1 YB-06265 / 90890-06706 (4) Install the dial gauge onto the lower unit and have the dial gauge plunger contact the mark on the backlash indicator.

6670

Magnetic-base plate................. 2 YB-07003 / 90890-07003 Dial gauge set ........................... 3 YU-03097 / 90890-01252 Magnetic base........................... 4 YU-34481 / 90890-06705 (5) Set the lower unit upside down. (6) Slowly turn the drive shaft clockwise and counterclockwise. When the drive shaft stops in each direction, measure the backlash.

6-72

LOWR

BACKLASH (REGULAR ROTATION MODELS)

2. Adjust: • Reverse gear shim Remove or add shim(s). Reverse gear backlash Less than 0.80 mm (0.031 in)

To be increased by (0.99 – M) × 0.63

More than 1.17 mm (0.046 in)

To be decreased by (M – 0.99) × 0.63

M: Measurement

6-73

Shim thickness

LOWR

SHIMMING (COUNTER ROTATION MODELS)

6500

6-74

SHIMMING (COUNTER ROTATION MODELS) (FOR USA AND CANADA)

LOWR

SELECTING THE PINION SHIMS NOTE: Find the shim thickness (T3) by selecting shims until the specified measurement (M) is obtained with the special tool.

6505

1. Measure: • Specified measurement (M) Out of specified value (M0) → Adjust.

Specified value (M0) = 1.00 + P/100 mm Measuring steps (1) Calculate the specified value (M0).

6520

6510

Example: If “P” is “+5”, then M0 = 1.00 + (+5)/100 mm = 1.00 + 0.05 mm = 1.05 mm If “P” is “–3”, then M0 = 1.00 + (–3)/100 mm = 1.00 – 0.03 mm = 0.97 mm

6-75

SHIMMING (COUNTER ROTATION MODELS) (FOR USA AND CANADA)

LOWR

(2) Install the pinion height gauge, drive shaft, thrust bearing 1, and shim(s) 2. Pinion height gauge YB-34432-6, -11 NOTE: If the original shim(s) is unavailable, start with a 0.50-mm shim.

6515

(3) Install the pinion and pinion nut.

Pinion nut 95 Nm (9.5 m • kgf, 69 ft • lb)

(4) Measure the specified measurement (M).

6520

2. Adjust: • Shim thickness (T3) Remove or add shim(s). Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: (M0) – (M) should be as close to “0” as possible.

6-76

LOWR

SHIMMING (COUNTER ROTATION MODELS) (FOR USA AND CANADA)

SELECTING THE REVERSE GEAR SHIMS NOTE: Find the shim thickness (T1) by selecting shims until the specified value (M0) is obtained with the special tool. 6525

1. Measure: • Specified measurement (M) Out of specified value (M0) → Adjust. Specified value (M0) = 25.30 + F/100 mm Measuring steps (1) Calculate the specified value (M0).

6527

6530

Example: If “F” is “+5”, then M0 = 25.30 + (+5)/100 mm = 25.30 + 0.05 mm = 25.35 mm If “F” is “–3”, then M0 = 25.30 + (–3)/100 mm = 25.30 – 0.03 mm = 25.27 mm

6-77

LOWR

SHIMMING (COUNTER ROTATION MODELS) (FOR USA AND CANADA)

(2) Install the roller bearing 1, thrust bearing 2, and shim(s) 3. NOTE: If the original shim(s) is unavailable, start with a 0.50-mm shim. (3) Measure the specified measurement (M).

6540

2. Adjust: • Shim thickness (T1) Remove or add shim(s). Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: (M0) – (M) should be as close to “0” as possible.

SELECTING THE FORWARD GEAR SHIMS NOTE: Find the shim thickness (T2) by selecting shims until the specified value (M0) is obtained with the special tool. 6545

1. Measure: • Specified measurement (M) Out of specified value (M0) → Adjust. M

Specified value (M0) = 2.70 – R/100 mm

6556

6-78

LOWR

SHIMMING (COUNTER ROTATION MODELS) (FOR USA AND CANADA)

Measuring steps (1) Calculate the specified value (M0). NOTE: • “R” is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units. If the “R” mark is missing or unreadable, assume an “R” value of “0”, and check the backlash when the unit is assembled. • If the “R” mark is negative (–), then add the “R” value to the measurement.

6550

Example: If “R” is “+5”, then M0 = 2.70 – (+5)/100 mm = 2.70 – 0.05 mm = 2.65 mm If “R” is “–3”, then M0 = 2.70 – (–3)/100 mm = 2.70 + 0.03 mm = 2.73 mm

(2) Install the shimming gauge, bearing, thrust washer, forward gear, and shim(s). M

Shimming gauge YB-34468-2 NOTE: • If the original shim(s) is unavailable, start with a 0.50-mm shim. • Turn the forward gear assembly a few times until the gear and bearing are horizontal.

6556

(3) Measure the specified measurement (M).

6-79

LOWR

SHIMMING (COUNTER ROTATION MODELS) (FOR USA AND CANADA)

2. Adjust: • Shim thickness (T2) Remove or add shim(s). Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm NOTE: (M0) – (M) should be as close to “0” as possible.

SELECTING THE PROPELLER SHAFT SHIMS NOTE: Find the shim thickness (T4) by selecting shims until the specified measurement is obtained with the special tool.

6560

1. Install: • Shim(s) 1 • Thrust bearing 2 • Propeller shaft 3 • Tapered roller bearing 4

6565

2. Measure: • Propeller shaft free play Out of specification → Adjust. Propeller shaft free play 0.30 ± 0.05 mm Magnetic base........................... 1 YU-34481 Dial gauge set ........................... 2 YU-03097

6570

3. Adjust: • Propeller shaft free play Remove or add shim(s). Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm

6-80

LOWR

SHIMMING (COUNTER ROTATION MODELS) (EXCEPT FOR USA AND CANADA)

SELECTING THE PINION SHIMS NOTE: Select the shim thickness (T3) by using the specified measurement(s) and the calculation formula. Select: • Shim thickness (T3)

6575

Selecting steps (1) Measure (M3). Digital caliper 90890-06704 NOTE: Install the bearing housing 1, thrust bearing 2, and washer 3.

6580

(2) Install the pinion and pinion nut.

Pinion nut 95 Nm (9.5 m • kgf, 69 ft • lb)

6585

6-81

LOWR

SHIMMING (COUNTER ROTATION MODELS) (EXCEPT FOR USA AND CANADA)

6590

Rounded numeral

More than

or less

0.00

0.02

0.00

0.02

0.05

0.02

0.05

0.08

0.05

0.08

0.10

0.08

Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm

6-82

LOWR

SHIMMING (COUNTER ROTATION MODELS) (EXCEPT FOR USA AND CANADA)

SELECTING THE REVERSE GEAR SHIMS NOTE: Select the shim thickness (T1) by using the specified measurement(s) and the calculation formula. Select: • Shim thickness (T1)

6595

Selecting steps (1) Measure (M1). Digital caliper 90890-06704 NOTE: • Measure the combined thickness of the roller bearing 1 and thrust bearing 2. • Turn the roller bearing outer race two or three times so the rollers seat. Then, measure the height of the bearing, as shown. • Perform the same measurement at three points on the roller bearing outer race. • Find the average of the measurements (M1). 6605

(2) Calculate the reverse gear shim thickness (T1). Reverse gear shim thickness (T1) (T1) = 25.3 + F/100 – M1 NOTE: • “F” is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units. If the “F” mark is missing or unreadable, assume an “F” value of “0”, and check the backlash when the unit is assembled. • If the “F” mark is negative (–), then subtract the “F” value from the measurement. 6610

6-83

LOWR

SHIMMING (COUNTER ROTATION MODELS) (EXCEPT FOR USA AND CANADA)

Example: If M1 is “24.80 mm” and F is “+5”, then T1 = 25.3 + (+5)/100 – 24.80 mm = 25.3 + 0.05 – 24.80 mm = 0.55 mm (3) Select the reverse gear shim(s). Calculated numeral at 1/100th place

Rounded numeral

More than

or less

0.00

0.02

0.00

0.02

0.05

0.02

0.05

0.08

0.05

0.08

0.10

0.08

Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm

SELECTING THE FORWARD GEAR SHIMS NOTE: Select the shim thickness (T2) by using the specified measurement(s) and the calculation formula. Select: • Shim thickness (T2)

6615

Selecting steps (1) Measure (M2). Shimming plate ........................ 1 90890-06701 Digital caliper ............................ 2 90890-06704 6620

NOTE: • Measure the height of the gear as shown. • Perform the same measurement at three points on the gear. • Find the average of the measurements (M2).

6-84

LOWR

SHIMMING (COUNTER ROTATION MODELS) (EXCEPT FOR USA AND CANADA)

(2) Calculate the forward gear shim thickness (T2). Forward gear shim thickness (T2) = M2 – 28.1 – R/100 NOTE: • “R” is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.01-mm units. If the “R” mark is missing or unreadable, assume a “R” value of “0”, and check the backlash when the unit is assembled. • If the “R” mark is negative (–), then subtract the “R” value from the measurement.

6625

Example: If M2 is “29.10 mm”, R is “+2”, then T2 = 29.10 – 28.1 – (+2)/100 mm = 29.10 – 28.1 – 0.02 mm = 0.98 mm (3) Select the forward gear shim(s) (T2). Calculated numeral at 1/100th place

Rounded numeral

More than

or less

0.00

0.02

0.05

0.08

0.10

Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm

6-85

LOWR

SHIMMING (COUNTER ROTATION MODELS) (EXCEPT FOR USA AND CANADA)

SELECTING THE PROPELLER SHAFT SHIMS NOTE: Find the shim thickness (T4) by selecting shims until the specified measurement is obtained with the special tool. 6560

1. Install: • Shim(s) 1 • Thrust bearing 2 • Propeller shaft 3 • Tapered roller bearing 4

6565

2. Measure: • Propeller shaft free play Out of specification → Adjust. Propeller shaft free play 0.30 ± 0.05 mm Magnetic base........................... 1 90890-06705 Dial gauge set ........................... 2 90890-01252

6640

3. Adjust: • Propeller shaft free play Remove or add shim(s). Available shim thickness 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and 0.50 mm

6-86

LOWR

BACKLASH (COUNTER ROTATION MODELS)

BACKLASH (COUNTER ROTATION MODELS)6 NOTE: • Do not install the water pump components when measuring the backlash. • Measure both the forward and reverse gear backlashes. • If both the forward and reverse gear backlashes are larger than specification, the pinion may be too high. • If both the forward and reverse gear backlashes are smaller than specification, the pinion may be too low.

MEASURING THE FORWARD GEAR BACKLASH 1. Measure: • Forward gear backlash Out of specification → Adjust. Forward gear backlash 0.32 - 0.45 mm (0.013 - 0.018 in) Measuring steps (1) Set the shift rod into the neutral position. Shift rod wrench YB-06052 / 90890-06052 (2) Install the propeller shaft housing puller so it pushes against the propeller shaft. 6645

6650

6-87

Center bolt 10 Nm (1.0 m • kgf, 7.2 ft • lb)

1 2 3 4

LOWR

BACKLASH (COUNTER ROTATION MODELS)

6655

Shim thickness

Less than 0.32 mm (0.013 in)

To be increased by (0.39 – M) × 0.63

More than 0.45 mm (0.018 in)

To be decreased by (M – 0.39) × 0.63

M: Measurement

MEASURING THE REVERSE GEAR BACKLASH 1. Measure: • Reverse gear backlash Out of specification → Adjust. Reverse gear backlash 0.80 - 1.12 mm (0.031 - 0.044 in)

6-88

LOWR

BACKLASH (COUNTER ROTATION MODELS)

Measuring steps (1) Set the shift rod into the neutral position. Shift rod wrench YB-06052 / 90890-06052 (2) Load the reverse gear by installing the propeller without the spacer and then tighten the propeller nut.

6645

Propeller nut 5 Nm (0.5 m • kgf, 3.6 ft • lb)

(3) Install the backlash indicator onto the drive shaft (on the 22.4 mm (0.88 in) diameter portion of the drive shaft). Backlash indicator .................... 1 YB-06265 / 90890-06706 6710

(4) Install the dial gauge onto the lower unit and have the dial gauge plunger contact the mark on the backlash indicator. Magnetic-base plate................. 2 YB-07003 / 90890-07003 Dial gauge set ........................... 3 YU-03097 / 90890-01252 Magnetic base........................... 4 YU-34481 / 90890-06705 (5) Set the lower unit upside down. (6) Turn the shift rod into the reverse position with the shift rod wrench. (7) Turn the drive shaft clockwise until the clutch dog is fully engaged.

6715

(8) Turn the shift rod into the neutral position with the shift rod wrench. (9) Turn the drive shaft counterclockwise approximately 30˚ more.

6720

6-89

LOWR

BACKLASH (COUNTER ROTATION MODELS)

(10) Turn the shift rod into the reverse position with the shift rod wrench. (11) Slowly turn the drive shaft clockwise and counterclockwise. When the drive shaft stops in each direction, measure the backlash. NOTE: When measuring the reverse gear backlash, turn the shift rod wrench towards the reverse position with force.

6725

2. Adjust: • Reverse gear shim Remove or add shim(s). Reverse gear backlash Less than 0.80 mm (0.031 in)

To be decreased by (0.96 – M) × 0.68

More than 1.12 mm (0.044 in)

To be increased by (M – 0.96) × 0.68

M: Measurement

6-90

Shim thickness

BRKT

CHAPTER 7 BRACKET UNIT STEERING HANDLE ....................................................................................... 7-1 REMOVING/INSTALLING THE STEERING HANDLE ............................. 7-1 DISASSEMBLING/ASSEMBLING THE TILLER HANDLE ....................... 7-2 DISASSEMBLING/ASSEMBLING THE STEERING BRACKET ............... 7-5 BOTTOM COWLING....................................................................................... 7-8 REMOVING/INSTALLING THE BOTTOM COWLING ............................. 7-8 DISASSEMBLING/ASSEMBLING THE BOTTOM COWLING (OIL INJECTION MODELS)................................................................... 7-10 DISASSEMBLING/ASSEMBLING THE BOTTOM COWLING (PRE-MIXED MODELS) ......................................................................... 7-13 SHIFT ROD ASSEMBLY ............................................................................... 7-15 DISASSEMBLING/ASSEMBLING THE SHIFT ROD ASSEMBLY......... 7-15 UPPER CASE ASSEMBLY............................................................................ 7-17 REMOVING/INSTALLING THE UPPER CASE ASSEMBLY .................. 7-17 DISASSEMBLING/ASSEMBLING THE UPPER CASE ASSEMBLY............................................................................................ 7-18 EXHAUST MANIFOLD ASSEMBLY............................................................. 7-21 DISASSEMBLING/ASSEMBLING THE EXHAUST MANIFOLD ASSEMBLY............................................................................................ 7-21 CLAMP BRACKETS ...................................................................................... 7-23 REMOVING/INSTALLING THE CLAMP BRACKETS (EXCEPT FOR E115AMH, E115AWH) .................................................. 7-23 REMOVING/INSTALLING THE CLAMP BRACKETS (FOR E115AMH, E115AWH) ................................................................. 7-25 INSPECTING THE SHOCK ABSORBER (E115AMH, E115AWH) ......... 7-28 STEERING ARM............................................................................................ 7-29 REMOVING/INSTALLING THE STEERING ARM.................................. 7-29 SWIVEL BRACKET ASSEMBLY................................................................... 7-30 DISASSEMBLING/ASSEMBLING THE SWIVEL BRACKET ASSEMBLY (EXCEPT FOR E115AMH, E115AWH).............................. 7-30 DISASSEMBLING/ASSEMBLING THE SWIVEL BRACKET ASSEMBLY (FOR E115AMH, E115AWH) ............................................ 7-32

BRKT POWER TRIM AND TILT UNIT..................................................................... 7-35 REMOVING/INSTALLING THE POWER TRIM AND TILT UNIT........... 7-35 REMOVING THE POWER TRIM AND TILT UNIT ................................. 7-36 BLEEDING THE POWER TRIM AND TILT UNIT ................................... 7-36 RESERVOIR AND POWER TRIM AND TILT MOTOR ................................. 7-38 REMOVING/INSTALLING THE RESERVOIR AND POWER TRIM AND TILT MOTOR................................................................................. 7-38 INSPECTING THE RESERVOIR.............................................................. 7-39 INSPECTING THE GEAR PUMP HOUSING FILTER ............................. 7-39 INSTALLING THE POWER TRIM AND TILT MOTOR........................... 7-40 FILLING THE RESERVOIR...................................................................... 7-41 BLEEDING THE POWER TRIM AND TILT UNIT ................................... 7-41 MEASURING THE HYDRAULIC PRESSURE ........................................ 7-43 TILT RAM ASSEMBLY AND GEAR PUMP UNIT........................................ 7-46 REMOVING/INSTALLING THE TILT RAM ASSEMBLY AND GEAR PUMP UNIT ................................................................................ 7-46 REMOVING THE TILT RAM END SCREW ............................................ 7-48 REMOVING THE GEAR PUMP UNIT .................................................... 7-48 DISASSEMBLING THE GEAR PUMP UNIT .......................................... 7-48 INSPECTING THE TILT RAM ................................................................. 7-49 INSPECTING THE GEAR PUMP UNIT .................................................. 7-49 ASSEMBLING THE GEAR PUMP UNIT ................................................ 7-50 INSTALLING THE GEAR PUMP UNIT................................................... 7-51 INSTALLING THE TILT RAM ASSEMBLY ............................................ 7-51 TRIM RAM ASSEMBLIES AND FREE PISTON ........................................... 7-53 REMOVING/INSTALLING THE TRIM RAM ASSEMBLIES AND FREE PISTON ........................................................................................ 7-53 REMOVING THE TRIM RAM END SCREWS ........................................ 7-54 REMOVING THE FREE PISTON............................................................. 7-54 INSPECTING THE TRIM RAMS ............................................................. 7-55 INSPECTING THE FREE PISTON........................................................... 7-55 INSPECTING THE TRIM RAM CYLINDERS .......................................... 7-55 INSTALLING THE FREE PISTON........................................................... 7-55 INSTALLING THE TRIM RAMS ............................................................. 7-56

1 2 3 4 5 6 7 8 9

BRKT

STEERING HANDLE

REMOVING/INSTALLING THE STEERING HANDLE

7001

Order 1 2 3 4 5 6 7 8 9 10 11

Job/Part 10-pin connector Throttle cable Shift cable Nut Steering friction rod Nut Steering handle assembly Nut Bolt Steering friction shaft Steering friction shaft holder

Qâ&#x20AC;&#x2122;ty 1 1 1 2 1 2 1 1 1 1 1

Remarks

For installation, reverse the removal procedure. 7-1

BRKT

STEERING HANDLE

7 DISASSEMBLING/ASSEMBLING THE TILLER HANDLE

7002

Order 1 2 3 4 5 6 7 8 9

Job/Part Throttle cable Nut Bolt Bushing Tiller handle bracket Plastic washer Metal washer Wave washer Screw

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 2 2 1 1

Remarks

Continued on next page.

7-2

BRKT

STEERING HANDLE

7002

Order 10 11 12 13 14 15 16 17 18

Job/Part Steering grip Washer Spring Bushing Grease nipple Bolt Bolt Gear cover Gasket

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 4 1 1

Remarks

Continued on next page.

7-3

BRKT

STEERING HANDLE

7002

Order 19 20 21 22 23 24 25 26

Job/Part Bolt Nut Bolt Friction piece Pin Gear Throttle shaft Gear case

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 1 1

Remarks

For assembly, reverse the disassembly procedure.

7-4

BRKT

STEERING HANDLE

7 DISASSEMBLING/ASSEMBLING THE STEERING BRACKET

7003

Order 1 2 3 4 5 6 7 8

Job/Part Nut Shift cable Cotter pin Shift cable bracket Nut Washer Washer Shift arm

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 1 1

Remarks

Not reusable

Continued on next page.

7-5

BRKT

STEERING HANDLE

7003

Order 9 10 11 12 13 14 15 16

Job/Part Bushing Bushing Collar Ball Spring Shift grip Bolt Shift arm guide

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 2 1

Remarks

Continued on next page.

7-6

BRKT

STEERING HANDLE

7003

Order 17 18 19 20 21 22 23 24

Job/Part Screw Bolt Main switch housing Nut Engine stop lanyard switch Bolt Main switch assembly Steering bracket

Qâ&#x20AC;&#x2122;ty 1 2 1 1 1 1 1 1

Remarks

For assembly, reverse the disassembly procedure.

7-7

BRKT

BOTTOM COWLING

REMOVING/INSTALLING THE BOTTOM COWLING

7010

Order 1 2 3 4 5 6

Job/Part Power unit Shift rod assembly Bolt Bracket Battery lead Hose guide Power trim and tilt lead

Q’ty

Remarks Refer to “POWER UNIT” on page 5-13.

1 2 1 2 1 1 Continued on next page.

Å Pre-mixed models

7-8

BRKT

BOTTOM COWLING

7010

Order 7 8 9 10 11 12

Job/Part Trim sensor lead Bolt Ground lead Speedometer hose Flushing hose Bottom cowling

Qâ&#x20AC;&#x2122;ty 1 4 1 1 1 1

Remarks

Salt water models For installation, reverse the removal procedure.

7-9

BRKT

BOTTOM COWLING

7 DISASSEMBLING/ASSEMBLING THE BOTTOM COWLING (OIL INJECTION MODELS)

7030

Order 1 2 3 4 5 6 7 8 9 10 11

Job/Part Rubber seal Collar Grommet Bolt Rear lock Front lock Pilot water outlet Pilot water hose Emergency cable Emergency cable Bolt

Qâ&#x20AC;&#x2122;ty 1 4 4 6 2 1 1 1 1 1 1

Remarks

(short) (long) Continued on next page.

7-10

BRKT

BOTTOM COWLING

7030

Order 12 13 14 15 16 17 18 19 20 21 22

Job/Part Cable holder Release cable Bolt Actuating lever Return spring Release lever Wave washer Grommet Bolt Cable holder Wire harness clamp

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 1 2 1 1 1

Remarks

Continued on next page.

7-11

BRKT

BOTTOM COWLING

7030

Order 23 24 25 26 27 28 29 30 31 32 33

Job/Part Cable guide Bolt Ground lead Bolt Cable guide Screw Holder Bolt Trailer switch holder Trailer switch Bottom cowling

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 1 2 1 1 1

Remarks

For assembly, reverse the disassembly procedure. 7-12

BRKT

BOTTOM COWLING

7 DISASSEMBLING/ASSEMBLING THE BOTTOM COWLING (PRE-MIXED MODELS)

7020

Order 1 2 3 4 5 6 7 8 9

Job/Part Bolt Clamp lever Bushing Hook Wave washer Pilot water hose Pilot water outlet Cable holder Wire harness clamp

Qâ&#x20AC;&#x2122;ty 3 3 6 3 3 1 1 2 1

Remarks

Continued on next page.

7-13

BRKT

BOTTOM COWLING

7020

Order 10 11 12 13 14 15 16

Job/Part Bolt Cable holder Screw Holder Grommet Collar Bottom cowling

Qâ&#x20AC;&#x2122;ty 1 1 3 3 4 4 1

Remarks

For assembly, reverse the disassembly procedure.

7-14

BRKT

SHIFT ROD ASSEMBLY

DISASSEMBLING/ASSEMBLING THE SHIFT ROD ASSEMBLY

7040

Order 1 2 3 4 5 6 7

Job/Part Screw Spring Ball Clip Shift rod lever Clip Bushing

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 1

Remarks

Continued on next page.

7-15

BRKT

SHIFT ROD ASSEMBLY

7040

Order 8 9 10 11 12 13

Job/Part Shift rod lever bracket Rubber seal Circlip Shift rod bracket Bushing Shift rod

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1

Remarks

For assembly, reverse the disassembly procedure.

7-16

BRKT

UPPER CASE ASSEMBLY

REMOVING/INSTALLING THE UPPER CASE ASSEMBLY

7050

Order

Job/Part

Q’ty

Lower unit Bottom cowling 1 2 3 4 5 6 7 8

Bolt Ground lead Screw Lower mount cover Cap nut Self-locking nut Upper case assembly Rubber seal

1 1 2 2 2 2 1 1

Remarks Refer to “LOWER UNIT (REGULAR ROTATION MODELS)” on page 6-1. Refer to “BOTTOM COWLING” on page 7-8. (upper case-to-swivel bracket)

For installation, reverse the removal procedure. 7-17

BRKT

UPPER CASE ASSEMBLY

7 DISASSEMBLING/ASSEMBLING THE UPPER CASE ASSEMBLY

7060

Order 1 2 3 4 5 6 7 8

Job/Part Bolt Upper mount bracket Upper mount Bolt Bolt Lower mount bracket Spring Lower mount

Qâ&#x20AC;&#x2122;ty 3 1 2 2 4 2 2 2

Remarks

Continued on next page.

7-18

BRKT

UPPER CASE ASSEMBLY

7060

Order 9 10 11 12 13 14 15 16 17

Job/Part Ground lead Bolt Bolt Bolt Muffler assembly Rubber seal Muffler Rubber seal Rubber seal

Qâ&#x20AC;&#x2122;ty 1 2 2 2 1 1 1 1 1

7-19

Remarks

X transom models X transom models X transom models Continued on next page.

BRKT

UPPER CASE ASSEMBLY

7060

Order 18 19 20 21

Job/Part Upper case Dowel pin Circlip Bushing

Qâ&#x20AC;&#x2122;ty 1 2 1 1

7-20

Remarks

X transom models X transom models For assembly, reverse the disassembly procedure.

BRKT

EXHAUST MANIFOLD ASSEMBLY

DISASSEMBLING/ASSEMBLING THE EXHAUST MANIFOLD ASSEMBLY

7070

Order 1 2 3 4 5 6 7 8 9

Job/Part Bolt Muffler Gasket Water tube Water seal Bolt Exhaust manifold Gasket Bolt

Qâ&#x20AC;&#x2122;ty 5 1 1 1 1 4 1 1 4

Remarks

Not reusable

Not reusable Continued on next page.

7-21

BRKT

EXHAUST MANIFOLD ASSEMBLY

7070

Order 10 11 12 13 14 15 16

Job/Part Lower exhaust manifold guide Gasket Upper exhaust manifold guide Plastic locking tie Flushing hose Plastic locking tie Cooling water hose

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 1 1

Remarks Not reusable Not reusable Salt water models Salt water models Not reusable For assembly, reverse the disassembly procedure.

7-22

BRKT

CLAMP BRACKETS

REMOVING/INSTALLING THE CLAMP BRACKETS (EXCEPT FOR E115AMH, E115AWH)

7080

Order

1 2 3 4 5 6 7 8

Job/Part Upper case assembly Rubber cap Grease nipple Ground lead Bolt Ground lead Anode bracket Anode Trim sensor

Q’ty

Remarks Refer to “UPPER CASE ASSEMBLY” on page 7-17.

3 3 1 4 1 2 1 1 Continued on next page.

7-23

BRKT

CLAMP BRACKETS

7080

Order 9 10 11 12 13 14 15

Job/Part Self-locking nut Bolt Clamp bracket bolt Starboard clamp bracket Port clamp bracket Bushing Swivel bracket assembly

Qâ&#x20AC;&#x2122;ty 1 2 1 1 1 2 1

Remarks

For installation, reverse the removal procedure.

7-24

BRKT

CLAMP BRACKETS

7 REMOVING/INSTALLING THE CLAMP BRACKETS (FOR E115AMH, E115AWH)

7085

Order

1 2 3 4 5 6 7

Job/Part Upper case assembly Rubber cap Grease nipple Ground lead Tilt pin Spring Bolt Ground lead

Q’ty

Remarks Refer to “UPPER CASE ASSEMBLY” on page 7-17.

3 3 1 1 1 4 1 Continued on next page.

7-25

BRKT

CLAMP BRACKETS

7085

Order 8 9 10 11 12 13 14 15 16

Job/Part Anode bracket Anode Circlip Shift pin Bolt Shock absorber bracket Self-locking nut Clamp bracket bolt Starboard clamp bracket

Qâ&#x20AC;&#x2122;ty 2 1 1 1 6 1 2 1 1

Remarks

Continued on next page.

7-26

BRKT

CLAMP BRACKETS

7085

Order 17 18 19 20 21 22 23 24

Job/Part Port clamp bracket Bushing Swivel bracket assembly Bolt Shaft pin Shock absorber Bushing Bushing

Qâ&#x20AC;&#x2122;ty 1 2 1 1 1 1 2 2

Remarks

For installation, reverse the removal procedure.

7-27

BRKT

CLAMP BRACKETS

INSPECTING THE SHOCK ABSORBER (E115AMH, E115AWH) WARNING This shock absorber contain highly compressed nitrogen gas. Before handling the shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the shock absorber. • Do not tamper or attempt to open the shock absorber. • Do not subject the shock absorber to an open flame or any other source of high heat. High heat can cause an explosion due to excessive gas pressure. • Do not deform or damage the shock absorber in any way. If the shock absorber is damaged, damping performance will suffer.

7086

Inspect: • Shock absorber Oil leaks/gas leaks/bends/damage → Replace.

7-28

BRKT

STEERING ARM

REMOVING/INSTALLING THE STEERING ARM

7090

Order

1 2 3 4 5 6 7 8 9

Job/Part Upper case assembly Circlip Steering arm yoke Washer Washer O-ring Steering arm Washer Bushing Swivel bracket assembly

Q’ty

Remarks Refer to “UPPER CASE ASSEMBLY” on page 7-17.

1 1 1 1 1 1 1 2 1 For installation, reverse the removal procedure. 7-29

BRKT

SWIVEL BRACKET ASSEMBLY

DISASSEMBLING/ASSEMBLING THE SWIVEL BRACKET ASSEMBLY (EXCEPT FOR E115AMH, E115AWH)

7100

Order 1 2 3 4 5 6

Job/Part Steering arm Nut Trim stopper Bolt Spring holder Spring Pin

Q’ty

Remarks Refer to “STEERING ARM” on page 7-29.

2 2 1 1 1 2 Continued on next page.

7-30

BRKT

SWIVEL BRACKET ASSEMBLY

7100

Order 7 8 9 10 11

Job/Part Starboard tilt stop lever Port tilt stop lever Bushing Bushing Tilt stop lever joint assembly

Qâ&#x20AC;&#x2122;ty 1 1 2 2 1

Remarks

For assembly, reverse the disassembly procedure.

7-31

BRKT

SWIVEL BRACKET ASSEMBLY

7 DISASSEMBLING/ASSEMBLING THE SWIVEL BRACKET ASSEMBLY (FOR E115AMH, E115AWH)

7105

Order 1 2 3 4 5 6 7 8 9 10

Job/Part Steering arm Bolt Spring holder Spring Pin Starboard tilt stop lever Port tilt stop lever Bushing Bushing Tilt stop lever joint assembly Cotter pin

Q’ty 1 1 1 2 1 1 2 2 1 1

Remarks Refer to “STEERING ARM” on page 7-29.

Not reusable Continued on next page.

7-32

BRKT

SWIVEL BRACKET ASSEMBLY

7105

Order 11 12 13 14 15 16 17 18 19 20

Job/Part Collar Hook Cotter pin Starboard control lever Port control lever Bushing Screw Cap Tilt lock rod Spring

Qâ&#x20AC;&#x2122;ty 1 1 1 1 1 2 2 2 1 1

Remarks

Not reusable

Continued on next page.

7-33

BRKT

SWIVEL BRACKET ASSEMBLY

7105

Order 21 22 23 24 25 26 27 28 29 30

Job/Part Cotter pin Reverse lock shaft Reverse lock arm Cotter pin Shaft pin Starboard reverse lock jaw Port reverse lock jaw Spring Bolt Spring holder

Qâ&#x20AC;&#x2122;ty 1 1 1 2 2 1 1 2 2 1

Remarks Not reusable

Not reusable

For assembly, reverse the disassembly procedure.

7-34

BRKT

POWER TRIM AND TILT UNIT

REMOVING/INSTALLING THE POWER TRIM AND TILT UNIT

7110

Order 1 2 3 4 5 6 7 8

Job/Part Tilt up the outboard Power trim and tilt lead Plastic locking tie Ground lead Circlip Upper mounting pin Lower mounting pin Power trim and tilt unit Collar

Qâ&#x20AC;&#x2122;ty 2 3 1 3 1 1 1 6

Remarks

Not reusable

For installation, reverse the removal procedure.

7-35

BRKT

POWER TRIM AND TILT UNIT

REMOVING THE POWER TRIM AND TILT UNIT WARNING After tilting up the outboard, be sure to support it with the tilt stop levers. Otherwise, the outboard could suddenly lower if the power trim and tilt unit should lose fluid pressure.

NOTE: Tilt up the outboard and then turn the tilt stop levers 1 to support it. Remove: • Power trim and tilt unit NOTE: Slightly lower the tilt ram assembly and then remove the power trim and tilt unit.

7120

BLEEDING THE POWER TRIM AND TILT UNIT NOTE: Install the power trim and tilt unit onto the outboard before bleeding. Bleed: • Air bubbles (from the power trim and tilt unit) Bleeding steps (1) Connect the battery leads to the battery. (2) Loosen the manual valve 1 by turning it counterclockwise until it stops.

7130

7-36

BRKT

POWER TRIM AND TILT UNIT

(3) Tilt up the outboard fully, then release it, and let it lower by its own weight. (4) Tighten the manual valve by turning it clockwise. (5) Let the power trim and tilt fluid settle for about 5 minutes. (6) Push and hold the power trim and tilt switch in the up position until the outboard is fully tilted up. (7) Turn the tilt stop levers to support the outboard. Then, let the power trim and tilt fluid settle for about 5 minutes. (8) Remove the reservoir cap 2 and check that fluid is up to the brim as shown. Add fluid if the level is below the brim. (9) Install the power trim and tilt reservoir cap. (10) Repeat the above steps two or three times until the power trim and tilt fluid is at the correct level.

7140

7150

7-37

BRKT

RESERVOIR AND POWER TRIM AND TILT MOTOR

REMOVING/INSTALLING THE RESERVOIR AND POWER TRIM AND TILT MOTOR

7160

Order

1 2 3 4 5 6 7 8

Job/Part Power trim and tilt unit Reservoir cap Bolt Reservoir Bolt Power trim and tilt motor O-ring Drive pin Gear pump housing filter

Q’ty

Remarks Refer to “POWER TRIM AND TILT UNIT” on page 7-35.

1 3 1 4 1 1 1 1 For installation, reverse the removal procedure.

7-38

BRKT

RESERVOIR AND POWER TRIM AND TILT MOTOR

WARNING • To prevent the hydraulic fluid from spurting out due to internal pressure, the outboard should be kept fully tilted up (the tilt rod at full length). • After removing the power trim and tilt motor or reservoir, do not push the tilt ram down. This may cause hydraulic fluid to spurt out from the port.

CAUTION: Do not wipe hydraulic system components with rags, paper, tissues, or the like, as fibers from such material will cause malfunctions if they enter the system.

INSPECTING THE RESERVOIR 1. Drain: • Power trim and tilt fluid 2. Inspect: • Reservoir Cracks/damage/leaks → Replace.

INSPECTING THE GEAR PUMP HOUSING FILTER Inspect: • Gear pump housing filter Damage/tears → Replace. Foreign matter → Clean.

7-39

BRKT

RESERVOIR AND POWER TRIM AND TILT MOTOR

INSTALLING THE POWER TRIM AND TILT MOTOR 1. Install: • Gear pump housing filter 1 • Drive pin 2 2. Fill: • Gear pump housing Recommended power trim and tilt fluid ATF Dexron II

7170

NOTE: Add power trim and tilt fluid until it reaches the top of the gear pump housing.

3. Bleed: • Air bubbles NOTE: • Remove all of the air bubbles with a syringe or suitable tool as shown. • Turn the gear pump gears with a screwdriver and then remove any air between the gear teeth.

7180

4. Install: • O-ring 1 • Power trim and tilt motor 2 • Bolt 3 NOTE: Align the armature shaft with the recess in the drive pin. 7190

7-40

BRKT

RESERVOIR AND POWER TRIM AND TILT MOTOR

FILLING THE RESERVOIR WARNING To prevent the hydraulic fluid from spurting out due to internal pressure, the tilt ram should be kept at full length. 1. Fill: • Reservoir Recommended power trim and tilt fluid ATF Dexron II 2. Inspect: • Power trim and tilt fluid level Level is low → Add power trim and tilt fluid to the proper level. 7200

BLEEDING THE POWER TRIM AND TILT UNIT NOTE: This bleeding must be done before installing the power trim and tilt unit onto the outboard. 1. Bleed: • Air bubbles (from the power trim and tilt unit) Bleeding steps (1) Set the power trim and tilt unit upright. (2) Connect the leads of the power trim and tilt on the battery terminals until the trim and tilt ram assemblies are fully compressed. 7210

NOTE: If the rams will not go down, refer to the following. A. Connect the leads of the power trim and tilt on the battery terminals until the trim and tilt ram assemblies are fully extended. Then, reverse the leads on the battery terminals until the trim and tilt ram assemblies are fully compressed.

7220

7-41

BRKT

RESERVOIR AND POWER TRIM AND TILT MOTOR

B. If step A was unsuccessful, connect the leads on the battery terminals and fully compress the tilt ram assembly by hand. C. If step B was unsuccessful, loosen the manual valve, compress the trim and tilt ram assemblies fully by hand, and then tighten the manual valve. Then, compress and extend the trim and tilt ram assemblies by connecting the leads on the battery terminals in the up and down positions. D. If step C was unsuccessful, disassemble, check, and correct any problems with the power trim and tilt unit.

(3) Connect the leads on the battery terminals in the up position until the trim and tilt ram assemblies are fully extended.

7220

(4) Remove the power trim and tilt reservoir cap and inspect that fluid is up to the brim as shown. Add power trim and tilt fluid if the level is below the brim. (5) Repeat the above steps two or three times until the fluid is at the correct level. 7230

2. Inspect: â&#x20AC;˘ Power trim and tilt unit operation Unsmooth operation â&#x2020;&#x2019; Bleed the power trim and tilt unit again.

7-42

BRKT

RESERVOIR AND POWER TRIM AND TILT MOTOR

MEASURING THE HYDRAULIC PRESSURE Inspect: • Hydraulic pressure Out of specification → Repair. Hydraulic pressure (with the power trim and tilt ram assemblies fully extended) 9.8 - 11.8 MPa (100 - 120 kg/cm2) (with the power trim and tilt ram assemblies fully compressed) 5.9 - 8.8 MPa (60 - 90 kg/cm2) NOTE: Before measuring the hydraulic pressure, bleed the power trim and tilt unit.

Measuring steps (1) Fully tilt up the power trim and tilt ram assemblies. (2) Remove the circlip 1. (3) Remove the manual valve 2 and install the up-relief valve attachment and hydraulic pressure gauge and tighten them to the specified torque. Up-relief valve attachment ...... 3 90890-06773 Hydraulic pressure gauge ........ 4 90890-06776

7240

Hydraulic pressure gauge 9 Nm (0.9 m • kgf, 6.5 ft • lb) Up-relief valve attachment 4 Nm (0.4 m • kgf, 2.9 ft • lb)

NOTE: Remove the manual valve and then quickly attach the special tools before any fluid comes out.

7250

7-43

BRKT

RESERVOIR AND POWER TRIM AND TILT MOTOR

(4) Connect the leads on the battery terminals in the down position until the power trim and tilt ram assemblies are fully compressed.

7210

(5) Connect the leads on the battery terminals in the up position until the power trim and tilt ram assemblies are fully extended. Then, measure the hydraulic pressure. Hydraulic pressure (with the power trim and tilt ram assemblies fully extended) 9.8 - 11.8 MPa (100 - 120 kg/cm2)

7220

(6) After measuring the hydraulic pressure, remove the special tools and quickly attach the down-relief valve attachment. Hydraulic pressure gauge ........ 4 90890-06776 Down-relief valve attachment. 5 90890-06774 7260

Hydraulic pressure gauge 9 Nm (0.9 m • kgf, 6.5 ft • lb) Down-relief valve attachment 4 Nm (0.4 m • kgf, 2.9 ft • lb)

(7) Remove the reservoir cap and check that fluid is up to the brim as shown. Add fluid if the level is below the brim. (8) Install the reservoir cap. (9) Connect the leads on the battery terminals in the down position until the power trim and tilt ram assemblies are fully compressed. Then, measure the hydraulic pressure.

7270

Hydraulic pressure (with the power trim and tilt ram assemblies fully compressed) 5.9 - 8.8 MPa (60 - 90 kg/cm2)

7-44

BRKT

RESERVOIR AND POWER TRIM AND TILT MOTOR

(10) After measuring the hydraulic pressure, connect the leads on the battery terminals in the up position until the power trim and tilt ram assemblies are fully extended. (11) Remove the special tools. (12) Install the manual valve and circlip. NOTE: After measuring the hydraulic pressure, bleed the power trim and tilt unit.

7280

7220

7-45

BRKT

TILT RAM ASSEMBLY AND GEAR PUMP UNIT

REMOVING/INSTALLING THE TILT RAM ASSEMBLY AND GEAR PUMP UNIT

7290

Order

1 2 3 4 5 6

Job/Part Reservoir and power trim and tilt motor Manual valve Tilt ram end screw Tilt ram assembly O-ring Bolt Gear pump unit

Q’ty

Remarks Refer to “RESERVOIR AND POWER TRIM AND TILT MOTOR” on page 7-38.

1 1 1 2 3 1 Continued on next page.

7-46

BRKT

TILT RAM ASSEMBLY AND GEAR PUMP UNIT

7290

Order 7 8 9 10 11 12

Job/Part Check valve assembly Gear pump Shuttle valve Check valve Up-relief valve assembly Down-relief valve assembly

Qâ&#x20AC;&#x2122;ty 1 1 2 2 1 1

Remarks

For installation, reverse the removal procedure.

7-47

BRKT

TILT RAM ASSEMBLY AND GEAR PUMP UNIT

REMOVING THE TILT RAM END SCREW Loosen: • Tilt ram end screw End screw wrench YB-06548 / 90890-06548 7300

NOTE: Hold the power trim and tilt unit in a vise using aluminum plates on both sides.

REMOVING THE GEAR PUMP UNIT Remove: • Bolt 1 • Gear pump unit 2 • O-ring 3 • Check valve 4

7310

NOTE: Place a container under the power trim and tilt unit.

DISASSEMBLING THE GEAR PUMP UNIT 1. Remove: • Bolt 1 • Pump gear 2 • Up-relief valve assembly 3 • Ball (4.76 mm/0.187 in) 4 • Shuttle valve 5 • Ball (3.18 mm/0.125 in) 6

7320

NOTE: When removing the pump gears, note their original direction and position for proper assembly.

7-48

BRKT

TILT RAM ASSEMBLY AND GEAR PUMP UNIT

2. Remove: • Check valves 1 and 2 NOTE: To remove the check valves, cover the gear pump housing with a clean cloth and then blow compressed air through holes a and b. 7330

INSPECTING THE TILT RAM Inspect: • Tilt ram Excessive scratches → Replace. Bends/excessive corrosion → Replace. Rust → Polish. (with 400 - 600 grit sandpaper)

INSPECTING THE GEAR PUMP UNIT Inspect: • Shuttle valves 1 • Check valve assemblies 2 Clogs/damage/wear → Replace. • Pump gears 3 Damage/wear → Replace the gear pump unit. • Up-relief valve assembly 4 • Down-relief valve assembly 5 Damage/wear → Replace the gear pump unit. • Balls 6 Damage/wear → Replace.

7335

7-49

BRKT

TILT RAM ASSEMBLY AND GEAR PUMP UNIT

ASSEMBLING THE GEAR PUMP UNIT CAUTION: Install all components in their original direction and position for proper assembly and operation.

1. Install: • Balls (3.18 mm/0.125 in) 1 • Shuttle valves 2 NOTE: Apply grease to the balls to prevent them from falling out of the gear pump. 7340

2. Install: • O-ring 1 • Ball (3.18 mm/0.125 in) 2 • Up-relief valve pin 3 • Spring 4 • Up-relief valve 5 • Up-relief valve assembly 6 7350

3. Install: • O-rings 1 • Check valves 2 • Balls (4.76 mm/0.187 in) 3 • Pump gears 4

4. Install: • Gear pump 1 • Bolt 2 • Filter 3 • O-ring 4 • Down-relief valve 5 • Filter 6

7360

NOTE: Tighten the bolts evenly and make sure the pump gears turn smoothly. 7370

7-50

BRKT

TILT RAM ASSEMBLY AND GEAR PUMP UNIT

INSTALLING THE GEAR PUMP UNIT 1. Install: • O-rings 1 • Ball 2 • Pin 3 • Check valve 4 • Check valve assembly 5 NOTE: When installing the check valve assembly, make sure the pin is on the tilt ram cylinder side as shown.

7380

2. Install: • Gear pump unit 1 • Bolt 2

7390

INSTALLING THE TILT RAM ASSEMBLY WARNING To prevent the hydraulic fluid from spurting out due to internal pressure, the tilt ram should be kept at full length. 1. Fill: • Tilt ram cylinder Recommended power trim and tilt fluid ATF Dexron II NOTE: Hold the power trim and tilt unit in a vise using aluminum plates on both sides.

7400

7-51

BRKT

TILT RAM ASSEMBLY AND GEAR PUMP UNIT

2. Fill: • Gear pump housing Recommended power trim and tilt fluid ATF Dexron II NOTE: Add power trim and tilt fluid through the hole a until the fluid level is to the top of the gear pump unit.

7410

3. Install: • Tilt ram assembly NOTE: Place the tilt ram end screw at the bottom of the tilt ram and install the tilt ram assembly into the tilt ram cylinder. 7420

4. Tighten: • Tilt ram end screw End screw wrench YB-06548 / 90890-06548

7430

7-52

Tilt ram end screw 130 Nm (13 m • kgf, 94 ft • lb)

BRKT

TRIM RAM ASSEMBLIES AND FREE PISTON

REMOVING/INSTALLING THE TRIM RAM ASSEMBLIES AND FREE PISTON

7440

Order

1 2 3 4 5 6 7

Job/Part Tilt ram assembly and gear pump unit Trim ram end screw Trim ram O-ring Seal ring Free piston O-ring Piston ring

Q’ty

Remarks Refer to “TILT RAM ASSEMBLY AND GEAR PUMP UNIT” on page 7-46.

2 2 2 2 1 1 1 For installation, reverse the removal procedure.

7-53

BRKT Å

TRIM RAM ASSEMBLIES AND FREE PISTON

REMOVING THE TRIM RAM END SCREWS

Loosen: • Trim ram end screw End screw wrench YB-06175-1A / 90890-06548 Å For USA and Canada ı Except for USA and Canada

7450

NOTE: Hold the power trim and tilt unit in a vise using aluminum plates on both sides.

REMOVING THE FREE PISTON 1. Drain: • Power trim and tilt fluid NOTE: After removing the trim ram assemblies, drain the fluid from the power trim and tilt unit. 2. Install: • Trim ram assemblies 1 NOTE: Finger-tighten the trim ram assemblies and then cover the tilt cylinder openings with a clean cloth. 3. Remove: • Free piston 2

7460

WARNING Never look into the tilt cylinder opening because the free piston and hydraulic fluid may be expelled out forcefully.

NOTE: Remove the free piston by blowing compressed air through the hole a.

7470

7-54

BRKT

TRIM RAM ASSEMBLIES AND FREE PISTON

INSPECTING THE TRIM RAMS Inspect: • Trim ram Excessive scratches → Replace. Bends/excessive corrosion → Replace. Rust → Polish. (with 400 - 600 grit sandpaper)

INSPECTING THE FREE PISTON Inspect: • Free piston Excessive scratches → Replace.

INSPECTING THE TRIM RAM CYLINDERS Inspect: • Trim ram cylinder Cracks/excessive scratches → Replace the power trim and tilt unit.

INSTALLING THE FREE PISTON 1. Fill: • Fluid passages Recommended power trim and tilt fluid ATF Dexron II Quantity 30 cm3 (1.0 US oz, 1.1 lmp oz) NOTE: • Hold the power trim and tilt unit in a vise using aluminum plates on both sides. • Add power trim and tilt fluid through the hole a.

7480

7-55

BRKT

TRIM RAM ASSEMBLIES AND FREE PISTON

2. Install: • Piston ring 1 • O-ring 2 • Free piston 3 NOTE: Push the free piston into the tilt ram cylinder until it bottoms out. 7490

INSTALLING THE TRIM RAMS WARNING Do not push the trim rams down while installing them into the trim ram cylinders. Otherwise, the hydraulic fluid may spurt out from the unit. 1. Fill: • Trim ram cylinders Recommended power trim and tilt fluid ATF Dexron II NOTE: Hold the power trim and tilt unit in a vise using aluminum plates on both sides. 7500

2. Fill: • Fluid passages Recommended power trim and tilt fluid ATF Dexron II NOTE: Add power trim and tilt fluid through holes a, b and c until all of the passages are filled.

7510

7-56

BRKT

TRIM RAM ASSEMBLIES AND FREE PISTON

3. Install: • Trim ram assemblies 1 NOTE: Place each trim ram end screw at the bottom of each trim ram and install them into the trim ram cylinders. 7520

4. Tighten: • Trim ram end screw

End screw wrench YB-06175-1A / 90890-06548

Trim ram end screw 80 Nm (8.0 m • kgf, 58 ft • lb)

7530

Å For USA and Canada ı Except for USA and Canada

7-57

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â&#x20AC;&#x201C;

CHAPTER 8 ELECTRICAL SYSTEMS ELECTRICAL COMPONENTS (OIL INJECTION EXCEPT FOR 115BETO MODELS).................................... 8-1 (Port view) ................................................................................................ 8-1 (Starboard view) ...................................................................................... 8-2 (Aft view) .................................................................................................. 8-3 ELECTRICAL COMPONENTS (PRE-MIXED AND 115BETO MODELS) ....... 8-4 (Port view) ................................................................................................ 8-4 (Starboard view) ...................................................................................... 8-5 (Aft view) .................................................................................................. 8-6 ELECTRICAL COMPONENTS ANALYSIS ..................................................... 8-7 DIGITAL CIRCUIT TESTER....................................................................... 8-7 MEASURING THE PEAK VOLTAGE........................................................ 8-7 PEAK VOLTAGE ADAPTOR..................................................................... 8-7 MEASURING A LOW RESISTANCE........................................................ 8-8 IGNITION SYSTEM (OIL INJECTION EXCEPT FOR 115BETO MODELS).................................... 8-9 IGNITION SYSTEM (PRE-MIXED AND 115BETO MODELS) ..................... 8-10 INSPECTING THE IGNITION SPARK GAP............................................ 8-11 MEASURING THE IGNITION SYSTEM PEAK VOLTAGE .................... 8-12 INSPECTING THE SPARK PLUG CAPS ................................................ 8-15 INSPECTING THE ENGINE STOP LANYARD SWITCH........................ 8-16 IGNITION CONTROL SYSTEM (OIL INJECTION MODELS) ...................... 8-17 IGNITION CONTROL SYSTEM (PRE-MIXED MODELS)............................. 8-18 INSPECTING THE THERMO SWITCH CONTINUITY............................ 8-19 INSPECTING THE OIL LEVEL SENSOR CONTINUITY......................... 8-19 INSPECTING THE EMERGENCY SWITCH............................................ 8-20 MEASURING THE OIL PUMP CONTROL UNIT.................................... 8-20 STARTING SYSTEM..................................................................................... 8-21 INSPECTING THE BATTERY ................................................................. 8-22 INSPECTING THE FUSES ...................................................................... 8-22 INSPECTING THE WIRE HARNESS CONTINUITY............................... 8-22 INSPECTING THE WIRE CONNECTIONS ............................................. 8-22 INSPECTING THE STARTER RELAY..................................................... 8-23 MEASURING THE FUEL ENRICHMENT VALVE................................... 8-23 INSPECTING THE NEUTRAL SWITCH.................................................. 8-23

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STARTER MOTOR ........................................................................................ 8-24 DISASSEMBLING/ASSEMBLING THE STARTER MOTOR.................. 8-24 REMOVING THE STARTER MOTOR PINION ....................................... 8-27 INSPECTING THE STARTER MOTOR PINION ..................................... 8-27 INSPECTING THE ARMATURE ............................................................. 8-27 MEASURING THE BRUSHES ................................................................ 8-28 CHARGING SYSTEM.................................................................................... 8-30 INSPECTING THE RECTIFIER/REGULATOR......................................... 8-31 MEASURING THE LIGHTING COIL OUTPUT PEAK VOLTAGE .......... 8-32 INSPECTING THE FUSES ...................................................................... 8-32 INSPECTING THE BATTERY ................................................................. 8-32 POWER TRIM AND TILT SYSTEM .............................................................. 8-33 INSPECTING THE FUSES ...................................................................... 8-34 INSPECTING THE BATTERY ................................................................. 8-34 INSPECTING THE POWER TRIM AND TILT RELAY............................. 8-34 INSPECTING THE TRAILER SWITCH CONTINUITY ............................ 8-35 MEASURING THE TRIM SENSOR RESISTANCE................................. 8-36 POWER TRIM AND TILT MOTOR................................................................ 8-37 DISASSEMBLING/ASSEMBLING THE POWER TRIM AND TILT MOTOR.......................................................................................... 8-37 REMOVING THE STATOR ..................................................................... 8-39 REMOVING THE BRUSH ....................................................................... 8-39 INSPECTING THE BRUSH ..................................................................... 8-39 INSPECTING THE ARMATURE ............................................................. 8-40 INSTALLING THE BRUSH ..................................................................... 8-41 INSTALLING THE ARMATURE ............................................................. 8-41 INSTALLING THE STATOR ................................................................... 8-41

1 2 3 4 5 6 7 8 9

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ELECTRICAL COMPONENTS (OIL INJECTION EXCEPT FOR 115BETO MODELS)

(Port view)

8010

1 2 3 4 5 6 7 8 9

Starter relay Power trim and tilt relay Starter motor Oil level sensor Oil pump control unit Emergency switch Trailer switch Fuse (30A) Fuse (20A)

Å To fuel enrichment valve ı To battery Ç To CDI unit and 10P coupler Î To power trim and tilt motor ‰ To trim sensor Ï To trim meter

8-1

B Br Lg R Sb W G/R L/R Y/R

: Black : Brown : Light green : Red : Sky blue : White : Green/red : Blue/red : Yellow/red

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ELECTRICAL COMPONENTS (OIL INJECTION EXCEPT FOR 115BETO MODELS)

(Starboard view)

8020

Thermo switch Lighting coil lead Rectifier/regulator Charge coil lead Pulser coil lead Fuel enrichment valve 7 Fuel hose 8 Oil hose 1 2 3 4 5 6

9 0 A B

Wire harness Speedometer hose Shift cable Throttle cable

Å ı Ç Î

To CDI unit To thermo switch To stator assembly To wire harness

‰ To trim sensor Ï To starter relay and starter motor Ì To oil level meter Ó To battery È To remote control Ô To trim meter  To remote oil tank

8-2

B G L P R Gy/B

: Black : Green : Blue : Pink : Red : Gray/black

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ELECTRICAL COMPONENTS (OIL INJECTION EXCEPT FOR 115BETO MODELS)

(Aft view)

8030

1 2 3 4 5

Thermo switch Ignition coil CDI unit Charge coil lead Pulser coil lead

Å ı Ç Î ‰ Ï

To oil pump control unit To relay assembly To charge coil To wire harness To 10P coupler To pulser coil

8-3

B Br P B/R B/W Gy/B L/R W/R

: Black : Brown : Pink : Black/red : Black/white : Gray/black : Blue/red : White/red

ELEC

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ELECTRICAL COMPONENTS (PRE-MIXED AND 115BETO MODELS)

(Port view)

8040

1 2 3 4

Fuse (20A) Starter relay Power trim and tilt relay Starter motor

Å ı Ç Î ‰ Ï

To fuel enrichment valve To battery To CDI unit and 10P coupler To power trim and tilt motor To trim sensor To trim meter

8-4

B Br Lg R Sb

: Black : Brown : Light green : Red : Sky blue

ELEC

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ELECTRICAL COMPONENTS (PRE-MIXED AND 115BETO MODELS)

(Starboard view)

8050

1 2 3 4 5 6 7 8

Rectifier/regulator Thermo switch Lighting coil lead Charge coil lead Pulser coil lead Fuel enrichment valve Shift cable Throttle cable

Å ı Ç Î ‰ Ï

To CDI unit To thermo switch To starter assembly To wire harness To trim sensor To starter relay and starter motor Ì To battery Ó To remote control È To trim meter

8-5

B G L O P R G/W Gy/B

: Black : Green : Blue : Orange : Pink : Red : Green/white : Gray/black

ELEC

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ELECTRICAL COMPONENTS (PRE-MIXED AND 115BETO MODELS)

(Aft view)

8060

1 2 3 4 5

Thermo switch Ignition coil CDI unit Charge coil lead Pulser coil lead

Å ı Ç Î ‰

To relay assembly To charge coil To wire harness To 10P coupler To pulser coil

8-6

B P B/W Gy/B

: Black : Pink : Black/white : Gray/black

ELEC

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ELECTRICAL COMPONENTS ANALYSIS ELECTRICAL COMPONENTS ANALYSIS DIGITAL CIRCUIT TESTER

Digital tester J-39299 / 90890-06752 NOTE: “ ” indicates a continuity of electricity which means a closed circuit at the respective switch position.

8090

MEASURING THE PEAK VOLTAGE

NOTE: • When checking the condition of the ignition system it is useful to know the peak voltage. • Cranking speed is dependant on many factors (e.g., fouled or weak spark plugs, a weak battery). If one of these is defective, the peak voltage will be lower than specification. • If the peak voltage measurement is not within specification the engine will not operate properly.

PEAK VOLTAGE ADAPTOR

NOTE: The peak voltage adaptor should be used with the digital circuit tester.

Peak voltage adaptor YU-39991 / 90890-03169

8100

8-7

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ELECTRICAL COMPONENTS ANALYSIS

NOTE: • When measuring the peak voltage, set the selector to the DC voltage mode. • Make sure the peak voltage adaptor leads are properly installed in the digital tester. • Make sure the positive pin (the “+” mark facing up as shown) on the peak voltage adaptor is installed into the positive terminal of the digital tester. • The test harness is needed for the following tests.

8120

Measuring steps (1) Disconnect the coupler connections. (2) Connect the test harness between the couplers. (3) Connect the peak voltage adaptor probes to the connectors which are being checked. (4) Start or crank the engine and observe the measurement. 8140

MEASURING A LOW RESISTANCE

When measuring a resistance of 10 Ω or less with the digital tester, the correct measurement cannot be obtained because of the tester’s internal resistance. To obtain the correct value, subtract the internal resistance from the displayed measurement. Correct value Displayed measurement – internal resistance NOTE: The internal resistance of the digital tester can be obtained by connecting both of its probes.

8-8

â&#x20AC;&#x201C;

ELEC

IGNITION SYSTEM (OIL INJECTION EXCEPT FOR

IGNITION SYSTEM (OIL INJECTION EXCEPT FOR 115BETO MODELS)

Br L R B/R

3 L

B/R

B/W

B/W B/W

B/W

1 W/B 4

W/B

W/R

W/G

W/Y

W/B

W/R

W/B B

W/Y W/G W/R W/B

W B B

8150

1 2 3 4 5

Spark plugs Ignition coils Charge coil Pulser coil CDI unit

B Br L R W

: Black : Brown : Blue : Red : White

8-9

B/R B/W W/B W/G W/R W/Y

: Black/red : Black/white : White/black : White/green : White/red : White/yellow

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IGNITION SYSTEM

IGNITION SYSTEM (PRE-MIXED AND 115BETO MODELS)

Br L R B/R

B/R

B/W

B/W B/W

B/W

1 L

1 4

W/B

W/R

W/G

W/Y

W/B

W/R

W/G W/Y W/B W/R B P W

6 B

8160

1 2 3 4 5 6

Spark plugs Ignition coils Charge coil Pulser coil CDI unit Engine stop lanyard switch

Å Except for E115AMH, E115AWH ı For E115AMH, E115AWH B Br L P R

: Black : Brown : Blue : Pink : Red 8-10

W B/R B/W W/B W/G W/R W/Y

: White : Black/red : Black/white : White/black : White/green : White/red : White/yellow

ELEC

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IGNITION SYSTEM

INSPECTING THE IGNITION SPARK GAP

WARNING • Do not touch any of the connections of the spark gap tester lead wires. • Do not let sparks leak out of the removed spark plug cap. • Keep flammable gas or liquids away, since this test can produce sparks.

8200

Inspect: • Ignition spark gap Above specification → Replace the spark plug. Below specification → Inspect the CDI unit output. 8210

Ignition spark gap 9 mm (0.4 in) Inspecting steps (1) Remove the spark plugs from the engine. (2) Connect a spark plug cap to the spark gap tester. (3) Set the spark gap length on the adjusting knob.

8220

Spark gap tester YM-34487 / 90890-06754 (4) Crank the engine and observe the spark through the discharge window of the spark gap tester.

8230

8240

8-11

ELEC

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IGNITION SYSTEM

MEASURING THE IGNITION SYSTEM PEAK VOLTAGE

WARNING When checking the peak voltage do not touch any of the connections of the digital tester lead wires.

NOTE: • If there is no spark or the spark is weak, continue with the ignition system test. • If a good spark is obtained, the problem is not with the ignition system, but possibly with the spark plug(s) or another component. 1. Measure: • CDI unit output peak voltage Above specification → Replace the ignition coil. Below specification → Measure the charge coil output peak voltage. CDI unit output peak voltage (oil injection except for 115BETO models) Black/white (B/W) – Black (B) 8250

r/min V

Circuit Cranking — 125

Loaded 1,500 140

3,500 145

CDI unit output peak voltage (pre-mixed and 115BETO models) Black/white (B/W) – Black (B) r/min V

8-12

Circuit Cranking — 85

Loaded 1,500 140

3,500 135

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IGNITION SYSTEM

E 2. Measure: • Charge coil output peak voltage Above specification → Measure the pulser coil output peak voltage. Below specification → Replace the charge coil.

Charge coil output peak voltage (oil injection except for 115BETO models) Red (R) – Brown (Br) r/min V

Circuit Cranking 170 160

Loaded 1,500 165

3,500 170

Black/red (B/R) – Blue (L) r/min V

8260

Circuit Cranking 45 45

Loaded 1,500 165

3,500 170

Test harness (4-pin) YB-38831 / 90890-06771

Charge coil output peak voltage (pre-mixed and 115BETO models) Red (R) – Brown (Br) r/min V

Circuit Cranking 95 105

Loaded 1,500 160

3,500 160

Black/red (B/R) – Blue (L) r/min V

Circuit Cranking 30 30

Loaded 1,500 160

3,500 160

Test harness (4-pin) YB-38831 / 90890-06771 Å Oil injection except for 115BETO models ı Pre-mixed and 115BETO models

8265

8-13

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IGNITION SYSTEM

E 3. Measure: • Pulser coil output peak voltage Above specification → Replace the CDI unit. Below specification → Replace the pulser coil.

Pulser coil output peak voltage (oil injection except for 115BETO models) White/red (W/R) – White/yellow (W/Y) White/black (W/B) – White/green (W/G) r/min V

Circuit Cranking 2.5 2.5

Loaded 1,500 7.0

3,500 12

Test harness (4-pin) YB-38831 / 90890-06771

8270

Pulser coil output peak voltage (pre-mixed and 115BETO models) White/red (W/R) – White/yellow (W/Y) White/black (W/B) – White/green (W/G) r/min V

Circuit Cranking 3.0 2.5

Loaded 1,500 8.0

3,500 12

Test harness (4-pin) YB-38831 / 90890-06771 Å Oil injection except for 115BETO models ı Pre-mixed and 115BETO models

8275

8-14

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IGNITION SYSTEM

INSPECTING THE SPARK PLUG CAPS

1. Inspect: • Spark plug cap Loose connection → Tighten. Cracks/damage → Replace. Replacement steps (for Canada, Europe and South Africa) (1) To remove the spark plug cap turn it counterclockwise. (2) To install the spark plug cap turn it clockwise until it is tight.

8280

Replacement steps (except for Canada, Europe and South Africa) (1) Remove the spark plug cap off of the lead. (2) Remove the spark plug cap spring. (3) Strip the insulation cover 5 mm (0.2 in) a and spread the core wires outward. (4) Fit the spark plug cap spring close to the spread core wires and bend the end of the spring around the lead. (5) Install the spark plug cap spring into the spark plug cap.

8285

8286

2. Measure: (for Canada, Europe and South Africa) • Spark plug cap resistance Out of specification → Replace. Spark plug cap resistance 4.0 - 6.0 kΩ 8290

8-15

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IGNITION SYSTEM

INSPECTING THE ENGINE STOP LANYARD SWITCH

Inspect: • Engine stop lanyard switch continuity Out of specification → Replace. Lead color

White (W) Remove the lock-plate Å. Install the lockplate ı. Push the button Ç.

8295

8-16

Black (B)

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IGNITION CONTROL SYSTEM

IGNITION CONTROL SYSTEM (OIL INJECTION MODELS)

8300

CDI unit Charge coil Pulser coil Thermo switch Oil pump control unit/ emergency switch 6 Oil level sensor 1 2 3 4 5

Å To sub-oil tank ı To oil level meter B Br L P R W

: Black : Brown : Blue : Pink : Red : White 8-17

Y B/R G/B G/R Gy/B L/R W/B Y/R

: Yellow : Black/red : Green/black : Green/red : Gray/black : Blue/red : White/black : Yellow/red

ELEC

â&#x20AC;&#x201C;

IGNITION CONTROL SYSTEM

IGNITION CONTROL SYSTEM (PRE-MIXED MODELS)

8305

1 Thermo switch 2 CDI unit

B : Black P : Pink Gy/B : Gray/black

8-18

ELEC

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IGNITION CONTROL SYSTEM

INSPECTING THE THERMO SWITCH CONTINUITY

Inspect: • Thermo switch continuity Out of specification → Replace. Thermo switch continuity temperature Pink (P) – Black (B) a 84 - 90 ˚C (183 - 194 ˚F) b 60 - 74 ˚C (140 - 165 ˚F)

8330

1 No continuity 2 Continuity

Å Temperature ı Time

Measuring steps (1) Place the thermo switch in a container filled with water. (2) Place a thermometer in the water. (3) Slowly heat the water. (4) Measure the continuity when the specified temperature is reached.

8340

INSPECTING THE OIL LEVEL SENSOR CONTINUITY Inspect: • Oil level sensor continuity Out of specification → Replace. Lead color Float position Black White Brown Red (B) (W) (Br) (R) Å ON Å OFF ı ON ı OFF Ç ON Ç OFF

Float distance a: 3.3 - 6.3 mm (0.13 - 0.25 in) b: 33.3 - 36.3 mm (1.31 - 1.43 in) c: 53.3 - 56.3 mm (2.10 - 2.22 in)

8690

8-19

ELEC

–

IGNITION CONTROL SYSTEM

INSPECTING THE EMERGENCY SWITCH

1. Inspect: • Emergency switch continuity Out of specification → Replace. Lead color

Switch position 8710

Blue (L) – Black (B)

Home a

No continuity

On b

Continuity

2. Inspect: • Emergency switch Does not automatically return to the home position → Replace.

MEASURING THE OIL PUMP CONTROL UNIT

Measure: • Oil pump control unit resistance Out of specification → Replace.

8720

Oil pump control unit resistance kΩ at 20˚C (68˚F) + Yellow (Y) Brown (Br) Blue (L) Black (B) Green/red (G/R) Green (G) White (W) Brown (Br) Red (R)

Yellow (Y)

*Yellow (Y)

Green/ red (G/R) 16.0 24.0

Brown (Br)

Blue (L)

*Blue (L)

Black (B)

3.2 - 4.8

12.0 18.0

4.8 - 7.2

1.6 - 2.4

1.6 - 2.4 8.0 - 12.0 6.4 - 9.6 8.0 - 12.0 8.0 - 12.0 8.0 - 12.0

∞

3.2 - 4.8

∞

1.6 - 2.4

3.2 - 4.8

∞

8.0 - 12.0

∞

8.0 - 12.0

∞

4.8 - 7.2

16.0 24.0 16.0 24.0 ∞

8.0 - 12.0 8.0 - 12.0

8-20

White (W)

Brown (Br)

Red (R)

16.0 24.0

8.0 - 12.0 8.0 - 12.0 8.0 - 12.0 8.0 - 12.0 8.0 - 12.0

8.0 - 12.0 8.0 - 12.0

∞

16.0 24.0

Green (G)

∞

∞ ∞

∞

16.0 24.0

16.0 24.0 16.0 24.0

16.0 24.0

∞

ELEC

â&#x20AC;&#x201C;

STARTING SYSTEM

8500

1 2 3 4 5 6

Fuse (20A) Fuse (30A) Fuel enrichment valve Starter motor Battery Starter relay

B Br L R

8-21

: Black : Brown : Blue : Red

ELEC

–

STARTING SYSTEM

INSPECTING THE BATTERY

Refer to “INSPECTING THE BATTERY” on page 3-21.

INSPECTING THE FUSES

1. Inspect: • Fuse holder continuity No continuity → Check the fuse holder leads. 2. Inspect: • Fuse holder lead continuity No continuity → Replace the fuse holder. Continuity → Inspect the fuse. 3. Inspect: • Fuse continuity No continuity → Replace. • Fuse rating Out of specification → Replace.

8510

Fuse rating 12 V - 20, 30 A

INSPECTING THE WIRE HARNESS CONTINUITY

Inspect: • Wire harness continuity No continuity → Replace.

INSPECTING THE WIRE CONNECTIONS Inspect: • Wire connections Poor connection → Properly connect.

8-22

ELEC

–

STARTING SYSTEM

INSPECTING THE STARTER RELAY

1. Inspect: • Brown lead terminal • Black lead terminal Poor connection → Properly connect. 2. Inspect: • Starter relay continuity No continuity → Replace.

8520

Inspecting steps (1) Connect the tester and battery between the starter relay terminals. Positive digital tester probe 1 → Starter relay terminal Negative digital tester probe 2 → Starter relay terminal Positive battery terminal → Brown lead 3 Negative battery terminal → Black lead 4

8521

(2) Inspect that there is continuity between the starter relay terminals.

MEASURING THE FUEL ENRICHMENT VALVE

Measure: • Fuel enrichment valve resistance Out of specification → Replace. Fuel enrichment valve resistance Blue (L) – Black (B) 3.4 ~ 4.0 Ω at 20 ˚C (68 ˚F)

INSPECTING THE NEUTRAL SWITCH

8525

Inspect: • Neutral switch continuity Out of specification → Replace. Lead color Neutral switch length Brown (Br) Brown (Br)

8526

8-23

18.5 ~ 19.5 mm (0.73 ~ 0.77 in)

19.5 ~ 20.5 mm (0.77 ~ 0.81 in)

ELEC

–

STARTER MOTOR

DISASSEMBLING/ASSEMBLING THE STARTER MOTOR

8530

Order

1 2 3 4 5 6

Job/Part Starter motor Bolt Starter motor bracket Clip Starter motor pinion stopper Spring Starter motor pinion

Q’ty

Remarks Refer to “RELAY ASSEMBLY AND STARTER MOTOR” on page 5-27.

2 1 2 1 1 1 Continued on next page.

8-24

ELEC

–

STARTER MOTOR

E 8

8530

Order 7 8 9 10 11 12 13 14

Job/Part Bolt Upper cover O-ring Washer Lower bracket O-ring Stator Armature

Q’ty 2 1 1 2 1 1 1 1

Remarks

Continued on next page.

8-25

ELEC

–

STARTER MOTOR

E 8

8530

Order 15 16 17 18 19 20 21

Job/Part Metal plate Nut O-ring Screw Brush assembly Spring Brush holder

Q’ty 1 1 1 2 1 3 1

Remarks

For assembly, reverse the disassembly procedure.

8-26

ELEC

–

STARTER MOTOR

REMOVING THE STARTER MOTOR PINION

Remove: • Clips NOTE: Slide the pinion stopper 1 down as shown and then remove the clips 2. 8540

INSPECTING THE STARTER MOTOR PINION

1. Inspect: • Starter motor pinion teeth Damage/wear → Replace. 2. Inspect: • Starter motor pinion movement Incorrect → Replace.

8550

NOTE: Rotate the starter motor pinion clockwise and make sure it moves smoothly. Also, rotate the starter motor pinion counterclockwise and make sure it locks.

INSPECTING THE ARMATURE 1. Inspect: • Commutator Foreign matter → Clean. (with 600 grit sandpaper)

8560

2. Measure: • Commutator diameter Out of specification → Replace. Commutator diameter limit 32.0 mm (1.26 in)

8570

8-27

ELEC

–

STARTER MOTOR

E 3. Inspect: • Commutator undercut Dirt/foreign matter → Clean. (with compressed air)

8580

4. Measure: • Commutator undercut a Out of specification → Replace the armature. Commutator undercut limit 0.2 mm (0.01 in) 8590

5. Inspect: • Armature continuity Out of specification → Replace. Armature continuity

8600

Commutator segments a

Continuity

Segment – Armature core b

No continuity

Segment – Armature shaft c

No continuity

MEASURING THE BRUSHES

1. Measure: • Brush length a Out of specification → Replace the brush assembly. Brush length limit 10.0 mm (0.39 in) 8610

8-28

ELEC

–

STARTER MOTOR

E 2. Inspect: • Brush assembly continuity Out of specification → Replace the brush assembly. Brush assembly continuity

8620

8-29

Brush 1 – Brush 2

Continuity

Brush 1 – Brush 3 Brush 2 – Brush 3 Brush holder 4 – Brush assembly holder 5

No continuity

ELEC

â&#x20AC;&#x201C;

CHARGING SYSTEM

8630

1 2 3 4

Rectifier/regulator Lighting coil Battery Fuses (30A)

B G R

8-30

: Black : Green : Red

ELEC

–

CHARGING SYSTEM

INSPECTING THE RECTIFIER/ REGULATOR

1. Inspect: (oil injection except for 115BETO models) • Rectifier/regulator continuity Out of specification → Replace. Rectifier/regulator continuity 1 2 Black (B) Green (G)

3 Red (R)

1 Black (B)

8640

2 Green (G)

∞

3 Red (R)

∞

: Continuity

∞ : No continuity NOTE: There are three green and one red terminal. The resistance between black and each of these terminals is the same. 2. Inspect: (pre-mixed and 115BETO models) • Rectifier/regulator continuity Rectifier/regulator continuity 2 1 Green/ Green (G) white (G/W) 1 Green (G)

3 4 Red (R) Black (B)

∞

2 Green/ white (G/W)

8650

3 Red (R)

∞

4 Black (B) : Continuity

∞ : No continuity

8-31

ELEC Å

–

CHARGING SYSTEM

MEASURING THE LIGHTING COIL OUTPUT PEAK VOLTAGE

8660

Measure: • Lighting coil output peak voltage Above specification → Replace the rectifier/regulator. Below specification → Replace the lighting coil.

Lighting coil output peak voltage (oil injection except for 115BETO models) Green (G) – Green (G)

8670

r/min V

Circuit Cranking 7.0 7.0

Loaded 1,500 13

3,500 11

Test harness (3-pin) YB-06770 / 90890-06770 Lighting coil output peak voltage (pre-mixed and 115BETO models) Green/white (G/W) – Green (G) r/min V

Circuit Cranking 6.0 6.0

Loaded 1,500 30

3,500 75

Å Oil injection except for 115BETO models ı Pre-mixed and 115BETO models

INSPECTING THE FUSES

Refer to “INSPECTING THE FUSES” on page 8-22.

INSPECTING THE BATTERY

Refer to “INSPECTING THE BATTERY” on page 3-21.

8-32

ELEC

–

POWER TRIM AND TILT SYSTEM

3 Sb R

FREE DOWN B

Lg Sb

Lg Sb Lg

B Lg Sb

Lg Sb

B Lg Sb

Lg Sb

R Sb Lg B

5 R

6 B P

B P

P P

8700

1 2 3 4 5 6 7

Power trim and tilt motor Power trim and tilt relay Trailer switch Fuse (20A) Fuse (30A) Battery Trim sensor

Å To remote control ı To trim meter

8-33

B G L Lg O P R Sb

: Black : Green : Blue : Light green : Orange : Pink : Red : Sky blue

ELEC

–

POWER TRIM AND TILT SYSTEM

INSPECTING THE FUSES

Refer to “INSPECTING THE FUSES” on page 8-22.

INSPECTING THE BATTERY

Refer to “INSPECTING THE BATTERY” on page 3-21.

INSPECTING THE POWER TRIM AND TILT RELAY

1. Inspect: • Power trim and tilt relay assembly continuity Out of specification → Inspect the power trim and tilt relay continuity. Power trim and tilt relay assembly continuity

8760

Sky blue (Sb) – Black (B) Continuity Light green (Lg) – Black (B) 2. Inspect: • Power trim and tilt relay continuity Out of specification → Replace. Power trim and tilt relay continuity

8770

8-34

Sky blue (Sb) lead – Black (B) lead Light green (Lg) lead – Black (B) lead

Continuity

Sky blue (Sb) lead – Terminal 1 Light green (Lg) lead – Terminal 1

Continuity

Sky blue (Sb) lead – Terminal 2 Light green (Lg) lead – Terminal 2

No continuity

Terminal 1 – Terminal 3

Continuity

Terminal 2 – Terminal 3

No continuity

ELEC

–

POWER TRIM AND TILT SYSTEM

3. Inspect: • Power trim and tilt relay operation No continuity → Replace. Inspecting steps (1) Connect the tester between the power trim and tilt relay terminals. (2) Connect a 12-V battery as shown. Sky blue (Sb) lead → Positive terminal Black (B) lead → Negative terminal

8775

Light green (Lg) lead → Positive terminal Black (B) lead → Negative terminal (3) Check that there is continuity between the power trim and tilt relay terminals.

INSPECTING THE TRAILER SWITCH CONTINUITY Inspect: • Trailer switch continuity Out of specification → Replace. Lead color Switch position Sky blue Red (R) (Sb)

8780

Up Free Down

8-35

Light green (Lg)

ELEC

–

POWER TRIM AND TILT SYSTEM MEASURING THE TRIM SENSOR RESISTANCE

Measure: • Trim sensor resistance Out of specification → Replace. Trim sensor resistance Pink (P) – Black (B) 239 - 379 Ω at 20 ˚C (68 ˚F)

8790

NOTE: Turn the lever 1 and measure the resistance as it gradually changes.

8-36

ELEC

–

POWER TRIM AND TILT MOTOR

DISASSEMBLING/ASSEMBLING THE POWER TRIM AND TILT MOTOR

8800

Order

1 2 3 4 5 6 7

Job/Part Power trim and tilt motor Screw Lead holder Screw Stator Armature O-ring Screw

Q’ty

Remarks Refer to “RESERVOIR AND POWER TRIM AND TILT MOTOR” on page 7-38.

1 1 2 1 1 1 2 Continued on next page.

8-37

ELEC

–

POWER TRIM AND TILT MOTOR

E 8

8800

Order 8 9 10 11 12 13

Job/Part Brush holder Brush Spring Lower cover Oil seal Bearing

Q’ty 2 2 2 1 1 1

Remarks

For assembly, reverse the disassembly procedure.

8-38

ELEC

–

POWER TRIM AND TILT MOTOR REMOVING THE STATOR

E 8

Remove: • Stator 1

CAUTION: • Keep the power trim and tilt motor leads inside the stator. • Do not allow grease or oil to contact the commutator.

8810

NOTE: • Remove the lead holder 2 and rubber spacer 3 from the stator and slide them towards the leads. • Hold the end of the armature shaft with a clean cloth and pull off the stator.

REMOVING THE BRUSH

1. Remove: • Sky blue power trim and tilt motor lead 1 NOTE: Hold the brush with a screwdriver as shown. Then, disconnect the sky blue lead. 8820

2. Remove: • Brush holders 1 • Brushes 2

CAUTION: Do not touch the bimetal a; touching it may affect the operation of the breaker. 8830

INSPECTING THE BRUSH 1. Measure: • Brush length a Out of specification → Replace. Brush length limit 4.8 mm (0.19 in) 8840

8-39

ELEC

–

POWER TRIM AND TILT MOTOR

2. Inspect: • Brush continuity No continuity → Replace.

CAUTION: Do not touch the bimetal a; touching it may affect the operation of the breaker. 8850

INSPECTING THE ARMATURE

1. Measure: • Commutator diameter a Out of specification → Replace. Commutator diameter limit 21.0 mm (0.83 in) 8860

2. Measure: • Commutator undercut a Out of specification → Replace the armature. Commutator undercut limit 0.85 mm (0.03 in) 8870

3. Inspect: • Armature continuity Out of specification → Replace. Armature continuity

8880

8890

8-40

Commutator segments

Continuity

Segment-laminations

No continuity

Segment-shaft

No continuity

ELEC

–

POWER TRIM AND TILT MOTOR INSTALLING THE BRUSH

E 8

Install: • Brushes 1 • Brush holders 2 • Power trim and tilt motor leads 3 • Screw 4

CAUTION: 8900

Do not touch the bimetal; touching it may affect the operation of the breaker.

INSTALLING THE ARMATURE

Install: • Armature 1 NOTE: Push the brushes into the holder and then install the armature. 8910

INSTALLING THE STATOR

Install: • Stator 1 NOTE: Place a clean cloth over the end of the armature shaft and carefully push the armature into the stator with a pair of pliers as shown.

8920

8-41

TRBL ANLS

CHAPTER 9 TROUBLE ANALYSIS TROUBLE ANALYSIS ..................................................................................... 9-1 TROUBLE ANALYSIS CHART ................................................................. 9-1

1 2 3 4 5 6 7 8 9

TRBL ANLS

TROUBLE ANALYSIS

NOTE: The following items should be checked before the “TROUBLE ANALYSIS CHART” is consulted. 1. The battery is charged and its specified gravity is within specification. 2. There are no incorrect wiring connections. 3. Wiring connections are properly secured and are not rusty. 4. The lanyard is installed onto the engine stop lanyard switch. 5. The shift position is in neutral. 6. Fuel is reaching the carburetor. 7. The rigging and engine setting are correct. 8. The engine is free from any “Hull problem”.

TROUBLE ANALYSIS CHART

POOR BATTERY CHARGING

IRREGULAR WARNING INDICATION

HARD SHIFTING

TILT MOTOR WILL NOT RUN

Check elements

LOOSE TILT HOLDING

LOOSE STEERING

OVERHEATING

LIMITED ENGINE SPEED

POOR PERFORMANCE

ENGINE WILL NOT STOP

POOR ACCELERATION

ENGINE STALLS

HIGH IDLING

ROUGH IDLING

HARD STARTING

ENGINE WILL NOT START

Trouble mode

Relative part

FUEL SYSTEM Fuel line Fuel filter Fuel joint Fuel pump Carburetors • Idle speed • Link adjustment • Pilot screw setting POWER UNIT Compression Reed valves Cylinder head gaskets Seal Cylinder block Crankcase Piston rings Pistons

9-1

Reference chapter

3 3 4 4 4 3 3 4 3 5 5 5 5 5 5 5

TRBL ANLS

TROUBLE ANALYSIS

POOR BATTERY CHARGING

IRREGULAR WARNING INDICATION

HARD SHIFTING

TILT MOTOR WILL NOT RUN

Check elements

LOOSE TILT HOLDING

LOOSE STEERING

OVERHEATING

LIMITED ENGINE SPEED

POOR PERFORMANCE

ENGINE WILL NOT STOP

POOR ACCELERATION

ENGINE STALLS

HIGH IDLING

ROUGH IDLING

HARD STARTING

ENGINE WILL NOT START

Trouble mode

Relative part

Bearings Thermostat Water passages LOWER UNIT Neutral position Dog clutch Gears Water inlets Water pump Propeller shaft(s) Shift rod joint/pin Shift cam Shift shaft Lower case BRACKET UNIT Bracket Rubber mount Shift rod POWER TRIM AND TILT UNIT Fluid level Relief valve Fluid passages Power trim and tilt motor ELECTRICAL Ignition system • Charge coil • Pulser coils • CDI unit • Ignition coils • Spark plugs

9-2

Reference chapter

5 5 5 6 6 6 6 6 6 6 6 6 6 7 7 7 3 7 — 7

8 8 8 8 3

TRBL ANLS

TROUBLE ANALYSIS

POOR BATTERY CHARGING

IRREGULAR WARNING INDICATION

HARD SHIFTING

TILT MOTOR WILL NOT RUN

Check elements

LOOSE TILT HOLDING

LOOSE STEERING

OVERHEATING

LIMITED ENGINE SPEED

POOR PERFORMANCE

ENGINE WILL NOT STOP

POOR ACCELERATION

ENGINE STALLS

HIGH IDLING

ROUGH IDLING

HARD STARTING

ENGINE WILL NOT START

Trouble mode

Relative part

Ignition control system • Lanyard switch • Thermo switch • Oil level sensor (engine oil tank) Starting system • Engine start switch • Starter relay • Fuel enrichment valve • Starter motor Charging system • Lighting coil • Rectifier/regulator • Fuses • Battery leads • Battery Power trim and tilt system • Trailer switch • Power trim and tilt relay • Trim sensor

9-3

Reference chapter

— 8 8 — 8 8 8 8 8 8 — — 8 8 8

WIRING DIAGRAM

COLOR CODE B Br G Gy L Lg O P

115TR, 130TR

0 Oil pump control unit

1 Power trim and tilt relay B

2 Power trim and tilt motor L

B L

B M

G/W : Gy/B : L/R : W/B : W/G : W/R : W/Y : Y/R :

Red Sky blue White Yellow Black/red Black/white Green/black Green/red

Green/white Gray/black Blue/red White/black White/green White/red White/yellow Yellow/red

G G G

L Br R B/R

A Emergency switch

L/R

B G

: : : : : : : :

R Sb W Y B/R B/W G/B G/R

G Charge coil

Black Brown Green Gray Blue Light green Orange Pink

H Lighting coil

B Oil level sensor

B W Br

: : : : : : : :

W/Y W/G

Gy/B

I Pulser coil

W/R W/B

J Rectifier/ regulator

1 Power trim and tilt relay

B R

B B

G G/B R

Y/R

4 Battery

R B

B B

B R

D Thermo switch

W/B

D Thermo switch B

E Spark plug

C CDI unit

Gy/B Gy/B

6 Fuse (30A)

3 Starter relay B

F Ignition coil B/W

Br Sb Lg

F Ignition coil B/W

G/R

E Spark plug

5 Starter motor

F Ignition coil

B/W

7 Fuse (20A)

K Oil pump (sub-oil tank)

B/W

E Spark plug R R Lg Sb Br B

E Spark plug 4

B/W

B/W B/W

B/W

L/R Y

Gy/B

B/R

W/R

L/R

G/B Lg Sb

B/R W/Y W/B

W/R

W/G W/B

L/R L/R

Br Lg

W G P Y B L Br G/R G/B Gy/B R R Lg Sb Br L

Gy/B

P Gy/B

M Trim sensor

R Lg Sb Br L G/B G/R

Sb Y

Gy/B

B G/B

G/R

R B

Gy/B

Br P

È To remote control

Gy/B

R Lg

G/B Gy/B

9 Trailer switch

W G P Y B

B L Br B/R

Gy/B

B Br Y

R Lg Sb

Sb R Lg

L W/B

G/R

B/R

W/B

R R Lg Sb Br L B

L B/R

W/Y

B W/B

B W/G

B/R

W/R

P L

Gy/B

Gy B

8 Fuel enrichment valve

Gy/B

L Oil level switch (sub-oil tank)

Gy/B B

É To trim meter Ê To oil level meter

YAMAHA MOTOR CORPORATION, USA

Printed in USA Oct. 2003 – 0.0 × 1 CR (E)